Vaginal insert method of manufacture

ABSTRACT

A method of manufacture for a vaginal insert. The vaginal insert may have a core, a cover, and a removal element. In various embodiments, the cover can be conformed to the vaginal insert.

BACKGROUND

Urinary incontinence is a problem among females. It is estimated that upto 50% of women occasionally leak urine involuntarily and thatapproximately 25% of women will seek medical advice in order to dealwith the problem. Stress incontinence, the most common type of urinaryincontinence, refers to the involuntary leakage of urine resulting froma rise in abdominal pressure. When involuntary urination occurs, itoften happens because of a rise in pressure in the bladder for whichthere is no compensating counter-pressure from the bladder neck orurethra. This is usually the result of the abnormal descent of thebladder neck and the urethra into a low position and away from theintra-abdominal pressure system. Known as “hypermobility”, this can bethe result of some injury to the support mechanism which normally keepsthe urethra and the bladder neck in a raised position along the backsideof the pubic bone.

The lowering of the bladder neck and the urethra that occur, forexample, when a woman coughs, sneezes, or laughs, can cause involuntaryleakage of urine. While many different factors may contribute to thedevelopment of stress incontinence, it is most prevalent among womenages 35-65 and those who have had multiple vaginal deliveries.

Stress incontinence is both aggravating and unpleasant for women and itcan also be embarrassing. Many women wear sanitary pads in order to dealwith stress incontinence although this is not a real solution to theproblem and it can be very inconvenient and unreliable. Surgicaltreatment may involve, among other things, elevation of the anteriorvaginal wall (Anterior Colporrhaphy), securing the paraurethal tissue tothe periosteum of the pubic bone (Marshall-Marchetti-Krantz operation),or elevation of the paracervical vaginal anterior wall to the Coopersligament (Burch Colpo suspension) in order to elevate the bladder neckabove the level of the pelvic floor and thereby distribute pressureequally to the bladder, the bladder neck, and the mid-urethra. Recently,a procedure known as “TVT” (Tension Free Vaginal Tape) was developed inwhich a mesh tape is implanted underneath the urethra (usuallymid-urethra) creating a hammock on which the urethra may kink during arise in intra-abdominal pressure. However, surgery is only suitable forsevere cases and the majority of women experiencing stress incontinencedoes not need, and certainly would rather avoid, surgical solutions.

One non-surgical treatment involves the use of vaginal inserts that areinserted into the vagina either by a medical practitioner or by thewoman herself. Most vaginal inserts are designed to apply pressureagainst the bladder neck so as to inhibit or completely block the flowof urine through the urethra. One problem with such devices is that theycompletely block the urethra and thus they need to be removed orcollapsed in order to allow the woman to urinate. To overcome thisdrawback vaginal inserts have been developed having specialized shapesthat do not completely block the urethra but these vaginal inserts tendto be large, uncomfortable, and intrusive. They also tend to causeirritation or soreness to the vagina.

Another common shortcoming is that most vaginal inserts also tend to bedifficult, painful or uncomfortable to insert and/or remove. In order tocorrectly inhibit urine flow, the vaginal insert needs to be properlypositioned in the vaginal canal. As a result, a doctor may be requiredto properly position the vaginal insert. In most cases, the vaginalinsert is adapted for remaining in the vagina for a prolonged period oftime (due to the time and expense of requiring a trained medicalprofessional to insert the vaginal insert). However, when positioned inthe vagina for an extended period of time, the vaginal insert may causevaginal infections, pressure ulcers, and/or bleeding.

A vaginal insert for treating urinary incontinence should have a sizeand shape configuration such that it can be comfortable during theinsertion and removal process. A vaginal insert for treating urinaryincontinence also needs to be capable of expanding following insertioninto the vagina and during wear in order to provide efficaciousincontinence protection. There is a need for a vaginal insert fortreating urinary incontinence which can be comfortable to wear in anat-rest state and which can provide incontinence prevention during ahigh stress event. There is a need for a method of manufacture of such avaginal insert for treating urinary incontinence. There is a need for amethod of manufacture for providing a vaginal insert which can have asize and shape configuration such that the vaginal insert can becomfortable during insertion, the vaginal insert can expand followinginsertion to provide urinary incontinence prevention, and the vaginalinsert can be collapsed to allow for a comfortable removal of thevaginal insert from the vagina.

SUMMARY

A method of manufacturing a vaginal insert comprising the steps ofproviding a core, the core comprising an anchoring element; a supportingelement; and a node connecting the anchoring element and the supportingelement; providing a cover blank; inserting the core into the coverblank by inverting the cover blank over the core resulting in a core andcover blank combination; attaching a removal element to the cover blank;and converting the cover blank into a cover. In various embodiments, thecover blank comprises a first layer of material and a second layer ofmaterial in a face-to-face relationship with the first layer of materialand a first side seam and a second side seam bonding the first layer ofmaterial to the second layer of material. In various embodiments, thecover blank comprises a rectangular, trapezoidal or trapezoid-like shapewhen viewed in a flat, two-dimensional configuration. In variousembodiments, the method further comprises the step of forming asupporting element seam in the cover blank. In various embodiments, thesupporting element seam of the cover blank can be located proximate thesupporting element of the core. In various embodiments, the step ofattaching the removal element to the cover blank further comprises thestep of rotating the core and cover blank combination. In variousembodiments, the method further comprises the step of conforming thecover to the core. In various embodiments, the step of conforming thecover to the core further comprises the step of attaching a band ofmaterial to the cover.

A method of manufacturing a vaginal insert comprising the steps ofproviding a core, the core comprising an anchoring element; a supportingelement; and a node connecting the anchoring element and the supportingelement; providing a cover blank, the cover blank comprising a firstlayer of material and a second layer of material in a face-to-facerelationship with the first layer of material; and a first side seam anda second side seam bonding the first layer of material to the secondlayer of material; forming a supporting element seam in the cover blank;inverting the cover blank over the core to form a core and cover blankcombination; attaching a removal element to the cover blank; and formingan anchoring element seam in the cover blank to convert the cover blankto a cover. In various embodiments, the cover blank comprises arectangular, trapezoidal or trapezoid-like shape in a flat,two-dimensional configuration. In various embodiments, the step ofattaching the removal element to the cover blank further comprises thestep of rotating the core and cover blank combination. In variousembodiments, the step of attaching the removal element to the coverblank further comprises the step of attaching the removal element in anarea of the cover blank which does not contain a side seam of the coverblank. In various embodiments, the method further comprises the step ofconforming the cover to the core. In various embodiments, the step ofconforming the cover to the core further comprises the step of attachinga band of material to the cover.

A method of manufacturing a vaginal insert comprising the steps ofproviding a core; providing a cover blank, the cover blank comprising afirst layer of material and a second layer of material in a face-to-facerelationship with the first layer of material; a first side seam and asecond side seam bonding the first layer of material to the second layerof material; top edges of the first layer of material and second layerof material in an unbonded configuration; and bottom edges of the firstlayer of material and the second layer of material in an unbondedconfiguration; pleating the bottom edges of the cover blank; forming asupporting element seam in the pleated bottom edges of the cover blank;inverting the cover blank over the core to form a core and cover blankcombination; pleating the top edges of the cover blank; and forming ananchoring element seam in the pleated top edges of the cover blank toconvert the cover blank to a cover. In various embodiments, the coverblank comprises a rectangular, trapezoidal, or trapezoid-like shape in aflat, two-dimensional configuration. In various embodiments, the methodfurther comprises the step of attaching a removal element. In variousembodiments, the step of attaching the removal element to the coverblank includes the step of rotating the core and cover blankcombination. In various embodiments, the step of attaching the removalelement to the cover blank further comprises the step of attaching theremoval element in an area of the cover blank which does not contain aside seam of the cover blank. In various embodiments, the method furthercomprises the step of conforming the cover to the core.

A method of conforming a cover to a vaginal insert comprising the stepsof providing a core, the core comprising an anchoring element; asupporting element; and a node connecting the anchoring element and thesupporting element; providing a cover blank, the cover blank comprisinga first layer of material and a second layer of material in aface-to-face relationship with the first layer of material; and a firstside seam and a second side seam bonding the first layer of material tothe second layer of material; inserting the core into the cover blank toform a core and cover blank combination; converting the cover blank to acover; and conforming the cover to the core in the area of the node ofthe core. In various embodiments, the cover blank comprises arectangular, trapezoidal or trapezoid-like shape in a flat,two-dimensional configuration. In various embodiments, the step ofconforming the cover to the core further comprises the step of reducingthe dimension of the cover at the node of the core. In variousembodiments, the step of reducing the dimension of the cover can furtherinclude one of the following: wrapping a band of material around thecover, twisting a portion of the material forming the cover, applying athermal treatment to the cover, or altering an elastic and/or extensibleproperty of the cover. In various embodiments, the step of reducing thedimension of the cover can further comprise a step of wrapping a band ofmaterial around the cover at the node of the core. In variousembodiments, the method further comprises the step of compressing theanchoring element of the core and sliding the band of material over thecompressed anchoring element of the core. In various embodiments, themethod further comprises the step of maintaining the reduced dimensionof the cover.

A method of conforming a cover to a vaginal insert comprising the stepsof providing a core, the core comprising an anchoring element; asupporting element; and a node connecting the anchoring element and thesupporting element; providing a cover blank, the cover blank comprisinga first layer of material and a second layer of material in aface-to-face relationship with the first layer of material; and a firstside seam and a second side seam bonding the first layer of material tothe second layer of material; inserting the core into the cover blank tocreate a core and cover blank combination; converting the cover blank toa cover; providing a band of material; encircling the band of materialaround the cover at the location of the node of the core; and attachingthe band of material to the cover at the location of the node of thecore. In various embodiments, the cover blank comprises a rectangular,trapezoidal or trapezoid-like shape in a flat, two-dimensionalconfiguration. In various embodiments, the step of inserting the coreinto the cover blank further comprises the step of inverting the coverblank over the core. In various embodiments, the method furthercomprises the step of compressing the anchoring element of the core andsliding the band of material over the compressed anchoring element ofthe core.

A method of conforming a cover to a vaginal insert comprising the stepsof providing a core, the core comprising a longitudinal axis; andsymmetry about the longitudinal axis; providing a cover blank, the coverblank comprising a longitudinal axis; and symmetry about thelongitudinal axis when viewed in a flat, two-dimensional configuration;inserting the core into the cover blank; converting the cover blank intoa cover; conforming the cover to the core. In various embodiments, thecore further comprises an anchoring element, a supporting element and anode connecting the anchoring element and the supporting element. Invarious embodiments, the cover blank further comprises a rectangular,trapezoidal or trapezoid-like shape. In various embodiments, the step ofconforming the cover to the core further comprises the step of reducingthe dimension of the cover at the node of the core. In variousembodiments, the step of reducing the dimension of the cover can furtherinclude one of the following: wrapping a band of material around thecover, twisting a portion of the material forming the cover, applying athermal treatment to the cover, or altering an elastic and/or extensibleproperty of the cover. In various embodiments, the step of reducing thedimension of the cover can further comprise a step of wrapping a band ofmaterial around the cover at the node of the core. In variousembodiments, the method further comprises the step of compressing theanchoring element of the core and sliding the band of material over thecompressed anchoring element of the core. In various embodiments, themethod further comprises step of maintaining the reduced dimension ofthe cover.

A method of conforming a cover to a core comprising the steps ofproviding a core; proving a cover blank; inserting the core within thecover blank; converting the cover blank into a cover; reducing adimension of the cover; and maintaining the reduced dimension of thecover. In various embodiments, the dimension of the cover is reduced ata narrowest portion of the core. In various embodiments, the corecomprises an anchoring element, a supporting element, and a nodeconnecting the anchoring element and the supporting element. In variousembodiments, the dimension of the cover is reduced at the node of thecore. In various embodiments, the step of reducing the dimension of thecover can further include one of the following: wrapping a band ofmaterial around the cover, twisting a portion of a material forming thecover, applying a thermal treatment to the cover, or altering an elasticand/or extensible property of the cover. In various embodiments, thestep of reducing the dimension of the cover can further comprise a stepof wrapping a band of material around the cover. In various embodiments,the step of maintaining the reduced dimension of the cover can furtherinclude a step of attaching the band to the cover.

A core insertion module comprising a bottom level comprising a corecompression tray; and a push rod positioned beneath the core compressiontray; a top level comprising a second pallet table; and a pre-tuck rodpositioned above the second pallet table; and a middle level between thebottom level and the top level and comprising a barrel drum. In variousembodiments, the core compression tray comprises at least one openingfor receiving a core therein. In various embodiments, the corecompression tray comprises a pair of jaws which shift at a 45° anglerelative to the core insertion module to compress a core loaded withinthe core compression tray. In various embodiments, the barrel drum iscapable of rotating 180°. In various embodiments, the second pallettable further comprises a transfer tube.

A core insertion module comprising a bottom level comprising a corecompression tray capable of transitioning from an open configuration toa closed configuration; and a push rod positioned beneath the corecompression tray; a top level comprising a second pallet table capableof moving in an up and down movement; and a pre-tuck rod positionedabove the second pallet table; and a middle level between the bottomlevel and the top level and comprising a barrel drum; and a core settool. In various embodiments, the core compression tray comprises atleast one opening for receiving a core therein. In various embodiments,the core compression tray comprises a pair of jaws which shift at a 45°angle relative to the core insertion module to compress a core loadedwithin the core compression tray. In various embodiments, the barreldrum is capable of rotating 180°. In various embodiments, the secondpallet table further comprises a transfer tube.

A compression tray comprising a front jaw, a rear jaw, guide blocks, atleast one opening for receiving an item to be compressed, and a pair ofspaced jaw connection mechanisms connecting the front and rear jaw. Invarious embodiments, the front jaw and the rear jaw shift at a 45° angleto compress a core loaded within the compression tray. In variousembodiments, the front jaw and the rear jaw shift with respect to eachother and maintain an aspect ratio of the opening of the compressiontray. In various embodiments, the jaw connection mechanisms can be oneof rack and pinion arrangements, slides, guide rails, or linearbearings.

A string and knot module comprising a stringing module comprising astring block; a string block clamp located internal to the string block;a needle; a string pulling clamp mechanism; and a string clampassociated with the string pulling clamp mechanism; a knotting modulecomprising an upper knotting block; a lower knotting block; and a firstfunnel and a second funnel, each of the first and second funnelsassociated with the lower knotting block. In various embodiments, thestringing module further comprises a source providing an air pressuredifferential. In various embodiments, the stringing module furthercomprises a scissor assembly. In various embodiments, the knottingmodule upper knotting block further comprises an upper portion, a lowerportion and a center pin positioned within the upper portion of theupper knotting block. In various embodiments, the upper and lowerportions of the upper knotting block can move independently of eachother. In various embodiments, the knotting module lower knotting blockfurther comprises an upper portion, a lower portion and a center pinpositioned within the upper portion of the lower knotting block. Invarious embodiments, the upper and lower portions of the lower knottingblock can move independently of each other. In various embodiments, theknotting module further comprises a string path associated with thelower and upper portions of the lower knotting block and the lower andupper portions of the upper knotting block. In various embodiments, aportion of the string path associated with the upper knotting block isat a 90° angle relative to a portion of the string path associated withthe lower knotting block.

A string and knot module comprising a stringing module comprising astring block; a string block clamp located internal to the string block;a needle; a string pulling clamp mechanism; a string clamp associatedwith the string pulling clamp mechanism; and a pair of cover blankclamps; a knotting module comprising an upper knotting block; a lowerknotting block; a first funnel and a second funnel, each of the firstfunnel and second funnels associated with the lower knotting block; anda string pincher. In various embodiments, the stringing module furthercomprises a source providing an air pressure differential. In variousembodiments, the stringing module further comprises a scissor assembly.In various embodiments, the upper and lower portions of the upperknotting block can move independently of each other. In variousembodiments, the upper and lower portions of the lower knotting blockcan move independently of each other. In various embodiments, theknotting module further comprises a string path associated with thelower and upper portions of the lower knotting block and the lower andupper portions of the upper knotting block. In various embodiments, aportion of the string path associated with the upper knotting block isat a 90° angle relative to a portion of the string path associated withthe lower knotting block.

A knot module comprising an upper knotting block comprising an upperportion; a lower portion; a center pin positioned within the upperportion of the upper knotting block; a lower knotting block comprisingan upper portion; a lower portion; a center pin positioned within theupper portion of the lower knotting block; a string path associated withthe lower and upper portions of the lower knotting block and associatedwith the lower and upper portions of the upper knotting block. Invarious embodiments, the upper portion and the lower portion of theupper knotting block can move independently of each other. In variousembodiments, the upper portion and the lower portion of the lowerknotting block can move independently of each other. In variousembodiments, a portion of the string path associated with the upperknotting block is at a 90° angle relative to the a portion of the stringpath associated with the lower knotting block.

A band forming module comprising a first web guide; a pair of feedrollers; a second web guide; a scissor mechanism; and a mandrel. Invarious embodiments, the mandrel is capable of rotation of 360°. Invarious embodiments, the mandrel comprises at least one end which ishollow. In various embodiments, the mandrel is connected to a vacuum. Invarious embodiments, the mandrel comprises a vacuum hole patternthereon. In various embodiments, the band forming module furthercomprises a servo motor for driving at least one of the feed rollers. Invarious embodiments, the band forming module further comprises a bondingmechanism.

A band forming module comprising a first web guide; a pair of feedrollers; a second web guide; a compressed air supply source; a scissormechanism; and a mandrel. In various embodiments, the mandrel is capableof rotation of 360°. In various embodiments, the mandrel comprises atleast one end which is hollow. In various embodiments, the mandrel isconnected to a vacuum. In various embodiments, the mandrel comprises avacuum hole pattern thereon. In various embodiments, the band formingmodule further comprises a servo motor for driving at least one of thefeed rollers. In various embodiments, the band forming module furthercomprises a bonding mechanism.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary embodiment of a vaginalinsert.

FIGS. 2-3 are perspective views of exemplary embodiments of a core.

FIGS. 4-6 are cross-sectional views of exemplary embodiments of thesupporting arms of a core.

FIG. 7 is a perspective view of an exemplary embodiment of a core.

FIG. 8 is a plan view of an exemplary embodiment of a possiblerelationship of the supporting arms to the longitudinal axis of a core.

FIG. 9 is a table showing exemplary performance ranges for medialdeflection and horizontal rotation (left/right from central axis), inaccordance with an exemplary embodiment of a core.

FIG. 10 is a perspective view of an exemplary embodiment of anapplicator for a vaginal insert.

FIG. 11 is a cross-sectional view of the applicator of FIG. 10.

FIG. 12 is a perspective view of the applicator of FIG. 10.

FIG. 13 is a side view of an exemplary embodiment of the component partsof a product package for a vaginal insert.

FIGS. 14A-14C are a series of charts illustrating exemplary corespecifications.

FIG. 15 is a vaginal insert performance graph correlating force exertedto core size, diameter and hardness.

FIG. 16 is a table showing performance characteristics for exemplarybasic core configurations.

FIG. 17 is an exemplary illustration of a portion of a process tomanufacture an embodiment of a cover blank.

FIG. 18 is an exemplary illustration of a portion of a process ofsequential manufacture of multiple cover blanks in a flat,two-dimensional configuration.

FIGS. 19-20 are top down views of exemplary embodiments of cover blanksin a flat, two-dimensional configuration.

FIG. 21 is a front view of a portion of an exemplary embodiment of afirst pallet onto which a cover blank can be loaded.

FIG. 22 is a top view of a portion of the first pallet of FIG. 21.

FIG. 23 is a side view of a portion of the first pallet of FIG. 21.

FIG. 24 is a front view of a portion of an exemplary embodiment of aloading fixture onto which a cover blank can be loaded.

FIG. 25 is a side view of a portion of the loading fixture of FIG. 24.

FIG. 26 is a front view of an exemplary embodiment of a cover blankloaded onto a portion of a first pallet.

FIG. 27 is a front view of an exemplary embodiment of a cover blankloaded onto a portion of a loading fixture.

FIG. 28 is a front view of an exemplary embodiment of a process ofloading a first pallet with a cover blank which was previously loaded ona loading fixture.

FIG. 29 is a front view of an exemplary embodiment of a portion of afirst pallet with two cover blanks prior to pleating of the coverblanks.

FIG. 30 is a top view of an exemplary schematic of a cover blank in anopen configuration prior to pleating.

FIG. 31 is a top view of an exemplary schematic of a cover blank duringpleating of the cover.

FIG. 32 is a top view of an exemplary schematic of a cover blank priorto withdrawal of the pleating bars.

FIG. 33 is a top view of an exemplary schematic of a pleated cover blankin position for bonding.

FIG. 34 is a side view of an exemplary schematic of an exemplary processto remove an area of trim from a cover blank.

FIG. 35 is a front view of an exemplary embodiment of a core insertionmodule.

FIG. 36 is a perspective view of an exemplary embodiment of the middleand lower levels of a core insertion module wherein the barrel drum andthe core compression tray can be in open positions.

FIG. 37 is a perspective view of an exemplary embodiment of the middleand lower levels of a core insertion module wherein the barrel drum andthe core compression tray can be in closed positions.

FIGS. 38A and 38B are perspective views of exemplary embodiments of acore compression tray.

FIGS. 39-42 are schematic illustrations of exemplary process steps ofinserting a core into a cover blank.

FIG. 43 is a front view of an exemplary embodiment of a partiallymanufactured vaginal insert with a removal element.

FIGS. 44-46 are schematic illustrations of exemplary process steps ofattaching a removal element to a cover.

FIGS. 47-50 are schematic illustrations of exemplary process steps ofknotting a removal element.

FIG. 51 is a schematic illustration of an exemplary string path.

FIG. 52-55 are schematic illustrations of exemplary process steps ofknotting a removal element.

FIG. 56 is a perspective view of an exemplary embodiment of a core andcover blank in a second pallet.

FIG. 57 is a perspective view of an exemplary embodiment of a core andcover blank in a third pallet.

FIGS. 58-64 are schematic illustrations of exemplary process steps inthe transfer of the core and cover blank combination from a secondpallet to a third pallet.

FIG. 65 is a perspective view of an exemplary embodiment of a pallettransfer module.

FIG. 66 is a front view of an exemplary embodiment of a pallet transfermodule.

FIG. 67 is a perspective view of an exemplary embodiment of acompressor.

FIG. 68 is a front view of an exemplary embodiment of a portion of athird pallet with a core and cover blank combination.

FIG. 69 is a top view of the third pallet of FIG. 68.

FIG. 70 is a schematic illustration of an exemplary process step in thepleating of a cover blank.

FIG. 71 is a schematic top view of the process step of FIG. 70.

FIG. 72 is a schematic illustration of an exemplary process step in thepleating of a cover blank.

FIG. 73 is a schematic top view of the process step of FIG. 72.

FIG. 74 is a schematic illustration of an exemplary process step in thepleating of a cover blank.

FIG. 75 is a schematic top view of an exemplary process step in thebonding of a cover blank.

FIG. 76 is a schematic illustration of an exemplary process step in thebonding of a cover blank.

FIG. 77 is a schematic illustration of an exemplary process step informing a band for a cover.

FIG. 78 is a schematic illustration of an exemplary pattern of vacuumholes on a mandrel.

FIG. 79 is a schematic illustration of an exemplary process of arranginga band on a cover.

FIG. 80 is a schematic illustration of an exemplary process of welding aband to a cover.

DETAILED DESCRIPTION

The present disclosure is generally directed towards a method ofmanufacturing a vaginal insert for the treatment of urinary incontinencein females. The vaginal insert can provide tension-free incontinencetreating support perpendicularly to the urethra (i.e., across theurethra). It should also be noted that for some women, the describedvaginal inserts can also be used as a treatment or part of a treatmentfor prolapse.

Vaginal Insert:

In various embodiments, the vaginal insert can be adapted to be stablein the vagina without significant longitudinal and/or rotationalmovement within the vagina. For example, supporting and anchoring armsof the vaginal insert can be designed to resist longitudinal movementwithin the vagina. As another example, the tips of the supporting and/oranchoring arms can be designed to resist rotational motion by workingwith the natural behavior of the vaginal wall, for example, by beingsized and/or shaped to induce the vaginal wall to at least partiallyenvelope the tip, thereby preventing rotational movement. Stability canalso be enhanced by using the supporting and/or anchoring arms toprovide contact between the vaginal insert and multiple points locatedspatially around the vaginal insert on the vaginal wall. In anembodiment, proper support-rendering positioning of the vaginal insertcan be considered to be where two supporting arms position themselvesone on each side of the urethra while at least one other supporting armprovides opposing force to the vaginal insert when the two supportingarms are subjected to force from the urethra during high-stress eventsthat cause the urethra to drop in the vagina.

In various embodiments, the vaginal insert can be adapted to bedisposable, worn only for a relatively short period of time and thendiscarded and replaced with a new vaginal insert (if needed).Alternatively, the vaginal insert can be recycled for use by sterilizingit between uses. The vaginal insert can be simple and easy to use andcan, optionally, be inserted in the same user-friendly manner that atampon is inserted into the vagina during menstruation, for example byusing an applicator. In an embodiment, the vaginal insert can beinserted in any orientation since the vaginal insert can naturallymigrate into a correct treatment position as a result of the vaginalinsert geometry. The vaginal insert can be small, exemplary sizesdescribed below, comfortable, and once inserted, the woman need notthink about it again until it is removed. As with insertion, removal canbe accomplished in a similar manner as a tampon, such as by pulling on aremoval element.

In various embodiments, the vaginal insert can include a core and aremoval element. In various embodiments, the vaginal insert can includea core, a cover, and a removal element. Each of these components will bedescribed in more detail below. An example of a vaginal insert 10 havinga core 12, a cover 14, and a removal element 16 can be seen in FIG. 1.

Referring to FIG. 2, a perspective view of an exemplary embodiment of acore 12 for a vaginal insert 10 for treating urinary incontinence isillustrated. For ease of description, the core 12 can be arranged arounda longitudinal axis 24 and divided into three basic elements. A topsection 18, inside the dashed box, can be provided which can serve asthe “anchoring” element for stabilizing the vaginal insert 10 within thevagina. There can be at least one of three types of anchoring: axialanchoring which can act in the direction along the central axis of thevagina, radial anchoring which can act side-to-side or substantiallyperpendicular to the central axis of the vagina and/or rotationalanchoring which will be described in more detail below. In anembodiment, the anchoring element 18 does not apply significant pressureto the wearer's vagina and/or urethra, which can thereby result inenhanced comfort. A bottom section 20, inside the dashed box, can beprovided which can serve as the “supporting” element for generatingsupport. In various embodiments, support can be generated at asub-urethral location, for example mid-urethra. Alternatively,additionally, and/or optionally, support can be generated at the bladderneck. In various embodiments, the supporting element 20 can provide atleast one type of anchoring, described above, to help anchor the vaginalinsert 10 in position within the vagina. In various embodiments, theroles of anchoring 18 and supporting 20 elements can be switched orshared. In an embodiment, the anchoring 18 and supporting 20 elements ofthe core 12 can function as an internal support structure for a cover14.

In an embodiment, an intermediate section can be provided which can actas a “node” 22 and which can connect anchoring 18 and supporting 20elements. The node 22 of core 12 can have a length which can be a smallportion of the overall length of the core 12. In various embodiments,the length of the node 22 can be less than about 15, 20 or 30% of theentire length of the core 12. In various embodiments, a node 22 having ashort length relative to the entire length of the core 12 can allow formore flexibility in varying the stiffness, the comfort, and the size ofthe core 12 when compared with a same length core 12 with a longer node22. Various design aspects of the core 12 can encourage stability of thevaginal insert 10 in the vagina, including: the longitudinal design ofthe core 12 which can incorporate anchoring arms 26 adapted to preventmovement of the vaginal insert 10 deeper into the vagina and/orsupporting arms 28 adapted to prevent movement of the vaginal insert 10towards the entrance to the vagina; specially adapted arm tips, such astips 30 and 32, which can resist rotational movement of the vaginalinsert 10 as they can be at least partially enveloped by the vaginalwall; an overall design which can take advantage of the vaginal tentingphenomenon; and, a multi-dimensional aspect which can allow variousarms, 26 and/or 28, of the core 12 to contact multiple and/or opposingvaginal surfaces concurrently.

In an exemplary embodiment, the anchoring element 18 and the supportingelement 20 can each have four arms, 26 and 28, respectively. In such anexemplary embodiment, two arms, 26 and 28, of each of the anchoring 18and supporting 20 elements, respectively, can generally exert pressuretowards the anterior vaginal wall and two arms, 26 and 28, of each ofthe anchoring 18 and supporting 20 elements, respectively, can generallyexert pressure towards the posterior vaginal wall adjacent the bowels.The distal part of the urethra extends into the vagina forming a recessbetween the urethral bulge and the vaginal wall. The arms, 26 and/or 28,which exert pressure anteriorly can fit within these natural recesses oneither side of the urethra. In various embodiments, the anchoringelement 18 and the supporting element 20 can each have more or lessarms, 26 and 28, respectively. For example, the anchoring element 18could have more anchoring arms 26 if there is concern about unwantedmovement of the vaginal insert 10.

Supporting arms 28 can cause elevation of the tissues around theurethra, optionally mid-urethra and/or bladder neck thereby acting as ahammock. This hammock can support the urethra in a tension free manner.In a woman who leaks urine during a stress event (e.g., when abdominalpressure rises during coughing, sneezing, etc.), the urethra sags downbut meets the hammock in its mid-part. The meeting of the urethra andthe hammock can cause an elevation of the intra-urethral pressure withresultant urinary continence.

In an embodiment, anchoring arms 26 can force the vaginal insert 10 toremain in situ within the vagina, unable to substantially move inwardsor outwards of the vagina, or to rotate within the vagina. One reasonthat this can occur can be as a result of the tendency of vaginal wallsto collapse and form an occluded lumen. The arms, 26 and/or 28, of thecore 12 can cause “tenting” of the vaginal walls on top of the arms withresultant sagging of the vaginal walls around the core 12, which canthereby stabilize the core 12. Additionally, in various embodiments,anchoring arms 26 can be flexible and/or elastic and/or resilient. Thisflexibility can enhance the anchoring arms 26 ability to prevent motionof the vaginal insert 10 further into the vagina. As force strives toexert itself on the vaginal insert 10 and move the vaginal insert 10further into the vagina, the flexible anchoring arms 26 can tend tospread apart. This spreading action of the anchoring arms 26 canincrease the friction between the vaginal insert 10 and the vaginalwall, thereby preventing movement further into the vagina. While theanchoring arms 26 can be flexible, it should be noted that they can berigid enough and/or can be configured to spread to prevent unwantedmotion of the vaginal insert 10 towards the entrance of the vagina. Inan embodiment, the anchoring arms 26 can be rigid but the node 22 can beflexible allowing the node 22 to provide flexible anchoring support.Movement towards the vaginal opening can also be resisted by thesupporting arms 28 which tend to widen radially when pulled outwardly.These features work with the tenting behavior of the vaginal walls whichalso helps to maintain the vaginal device 10 in place.

Referring to FIG. 2, the anchoring arms 26 can have tips 30 and thesupporting arms 28 can have tips 32. In various embodiments, the tips 30of the anchoring arms 26 can be rounded or spherical in nature, toprovide smooth surfaces (i.e., no corners or points) for the tenting ofthe vaginal wall. In various embodiments, the tips 32 of the supportingarms 28 and/or corners of core 12 can be blunted by a beveled edge bothalong the anchoring arms 26 and supporting arms 28 and at the tips 32,such as shown in FIGS. 2 and 3. In various embodiments, the tips 32 canbe slightly rounded and/or have a beveled edge. In an embodiment, thebeveled edge of the supporting arms 28 can reduce the overallcircumference of the core 12, relative to a completely spherical crosssection, when it is in a compressed mode for packaging within anapplicator. The difference between a core 12 with a beveledcross-section and a core 12 with a spherical cross-section can be seenin FIGS. 4 and 5. FIG. 6 illustrates a vaginal insert with a beveledcross-section in an applicator 40.

Also illustrated in FIG. 3 is a channel 34 which can transect the core12, whereby core 12 can be “held” during manufacturing and/or assemblyof the core 12 by placing a rod through channel 34. In an embodiment,channel 34 can be circular in shape. In an embodiment, channel 34 can bequadrilateral shaped. As illustrated in FIG. 6, the channel 34 can beaccessible through the quadrilateral shaped tunnel 36 created by thebeveled edges of supporting arms 28 when compressed for packaging in anapplicator 40. In an embodiment, channel 34 can be no bigger incircumference and/or dimension than tunnel 36.

In various embodiments, cores 12 of all sizes can have arms, bothanchoring 26 and supporting 28 arms, which can be the same length. Invarious embodiments, cores 12 of all sizes can have the same totallength when completely compressed inwardly. An example of an inwardlycompressed core 12 can be seen in FIG. 7. In an embodiment, anchoringarms 26 can be shorter than the supporting arms 28. In such anembodiment, the longitudinal length of the anchoring element 18 can beshorter than the longitudinal length of the supporting element 20 whenthe core 12 has been completely inwardly compressed. In such anembodiment, the node 22 is not necessarily located at the midpoint ofthe longitudinal axis 24. In such an embodiment, the core 12 may besymmetrical about the longitudinal axis 24, however, the core 12 is notnecessarily symmetrical about a lateral axis which can be located at themidpoint of the longitudinal axis 24. In an embodiment, anchoring arms26 can be a consistent size in a line-up of different sizes of cores 12even though the supporting arms 28 may vary in size and/or performance.Anchoring arms 26 can be the same size, in various embodiments, to easemanufacturing considerations. In various embodiments, the anchoring arms26 of the core 12 can operate independently, relative to thelongitudinal axis of the vagina, from the supporting arms 28.

In various embodiments, the difference between sizes of cores 12 can bethe resting angle at which supporting arms 28 protrude outwardlyrelative to the longitudinal axis 24 of the core 12. In variousembodiments, “larger” size cores 12 can have a larger radial spreadangle of supporting arms 28, hence they can be “shorter” when put nextto a smaller size core 12 (i.e., a core 12 which does not radiallyspread its supporting arms 28 as much). One potential advantage for sucha design can be that all cores 12, no matter the radial spread angle,can be inserted into one size of an applicator 40.

In an embodiment, the flexibility of various components of the core 12of a vaginal insert 10 can be designed both for function and for comfortto the user. In various embodiments, the core 12 of a vaginal insert 10can be designed with at least one of four aspects of flexibility whichcan assist in accomplishing these goals of function and comfort. Forexample, node 22 of core 12 can enable flexibility between the anchoringelement 18 and the supporting element 20, which can enable the vaginalinsert 10 to adjust to the arch structure of the vagina, as well as toadjust to any position taken by the wearer (e.g., standing, sitting,flexion, etc.) during daily activity. By being able to flex at the node22, pressure exerted on the vaginal wall can be reduced in relation to avaginal insert 10 that does not flex at the node 22.

Another flexibility aspect of the core 12 can relate to providingefficacy and comfort across varying vaginal planes, for example wherethe arms, 26 and/or 28, are adapted to contact the vaginal wall atvarying locations and/or angles of incidence, relative to each other,away from the longitudinal axis 24, such as shown in FIG. 8, which canallow the core 12 of the vaginal insert 10 to be adaptable to varyingvaginal topography/geometries by rotating either left or right from thecentral axis of each arm.

Another related aspect of flexibility can involve the ability of each ofthe arms, 26 and/or 28, to perform medial flexion, wherein each arm, 26and/or 28, can be flexible towards the longitudinal axis 24 whencompressed by the vaginal wall, enabling the adjustment of the vaginalinsert 10 to various vaginal diameters.

A fourth flexibility aspect can be the feature that each arm, 26 and/or28, can operate individually, for example, each arm, 26 and/or 28, beingable to twist clockwise and/or counterclockwise around its own axisallowing the core 12 of the vaginal insert 10 to overcome vaginalstructural variability from one point of contact to the next.

It should be noted that in various embodiments, at least one of thesefour featured aspects of flexibility can allow the core 12 of thevaginal insert 10 to render effective support regardless of vaginaldimension, vaginal shape, vaginal depth and/or through multiple planes.

FIG. 9 is a table showing exemplary performance ranges for medialdeflection (distance the tip of an arm or arms travel toward thelongitudinal axis 24 of the core 12) and horizontal rotation (left/rightmovement perpendicular to longitudinal axis 24), in accordance with anexemplary embodiment of a core 12. Numbers shown are in millimeters. Itshould be understood that horizontal rotation means rotation in axesperpendicular to the longitudinal axis of the vagina, particularly“right” and “left” when viewing the vagina in the longitudinal axisextending from the vaginal opening to the cervix. The ranges shown inFIG. 9 are amounts in mm that each arm could deviate from its naturalposition relative to the longitudinal axis 24 of the core 12. Regardingmedial deflection, it should be noted that when an arm is deflectedmedially, there is most often a corresponding arm on the other side ofthe core 12 which is also deflected medially (but maybe not the sameamount), therefore in an embodiment, medial deflection numbers (in mm)are divided by two in order to approximate medial deflection for asingle arm. It should also be noted that the numbers for medialdeflection in the table in FIG. 9 represent the full amount ofdeflection for a single arm assuming the corresponding arm does not moveat all. In addition, in some embodiments, the maximum amount of medialdeflection is dictated by two opposing arms contacting each other,preventing further medial deflection. In various embodiments, theminimum core 12 diameter that can be achieved is 12 mm, with each armrepresenting a 6 mm portion of that total.

In various embodiments, the core 12 can be made in a plurality of sizesand/or to exhibit specific performance characteristics, such as radialexpansion of the supporting arms 28. In various embodiments, thediameter of a radially expanded anchoring element 18 can range fromabout 30 to about 33 mm. In various embodiments, the diameter of aradially expanded supporting element 20 can range from about 34 mm toabout 52 mm. In various embodiments, the core 12 can also be made ofdifferent materials and/or materials exhibiting different performancecharacteristics, such as, for example, hardness. In various embodiments,the core 12 can be constructed of a material or materials which canexhibit a Shore A hardness of 30-80. In various embodiments, core 12 canbe manufactured in multiple Shore A hardnesses, including, but notlimited to, 40, 50 and 70.

In various embodiments, the core 12 can be constructed from a singlepiece (Monoblock). In various embodiments, the core 12 can have ananchoring element 18 and a supporting element 20 which can be providedas separate pieces (bi-polar) which can be attached to form the core 12.In various embodiments, each element, supporting 20 or anchoring 18, canbe constructed of two or more pieces.

Referring to FIG. 1, a perspective view of a core 12 enclosed within acover 14 provided with a removal element 16 is illustrated, inaccordance with an exemplary embodiment of the vaginal insert 10. Cover14 can be optionally any of the covers described in PCT/IL2004/000433;PCT/IL2005/000304; PCT/IL2005/000303; PCT/IL2006/000346;PCT/IL2007/000893; PCT/IL2008/001292; U.S. Provisional PatentApplication No. 60/719,422; U.S. Provisional Patent Application No.60/762,059; and, U.S. Provisional Patent Application No. 60/960,492.

In various embodiments, the cover 14 can be smooth. In variousembodiments, the cover 14 can be formed from woven or non-wovenmaterial. Woven material can include, but is not limited to, textilefabrics which can be made from rayon, cotton, polyolefins, or othersynthetic yarns. The synthetics can be either staple or continuousfilaments. Non-woven materials can include, but are not limited to,spunbond, bonded carded webs, and hydroentangled webs. In variousembodiments, the cover 14 can be constructed from a spunbond non-wovenmaterial. In various embodiments, the cover 14 can be treated with anaqueous solution to reduce frictional drag and to enhance the ease ofinsertion into and withdrawal from a woman's vagina. In variousembodiments, the cover 14 can be constructed of a non-woven materialsuch as a 33 gsm non-woven Fiberweb®, Catalog No. 097YLJO09P. In variousembodiments, the cover 14 can be constructed of a non-woven material,such as, for example, constructed of about 50% polypropylene and about50% polyethylene. In various embodiments, the cover 14 can beconstructed of nylon. In various embodiments, the cover 14 and theremoval element 16 can be constructed of the same unitary piece ofmaterial and/or at the same time and/or in the same process. In variousembodiments, the cover 14 and the removal element 16 can be constructedof separate pieces of material. In various embodiments, the cover 14 canbe constructed of a non-absorbent material. In various embodiments, thecover 14 can be flexible and/or stretchable. In various embodiments, thecover 14 can be formed from a heat-shrinkable material. In variousembodiments, the cover 14 can be formed from a material which can beextensible and/or elastic. In various embodiments, elements of the cover14 can be bonded, stitched, sutured, and/or welded together. In variousembodiments, the bonds, stitches, sutures, and/or welds can be locatedinside the cover 14 opposite the vaginal wall. In various embodiments,the cover 14 and/or the core 12 can be adapted to allow the free flow ofvaginal discharge.

In various embodiments, the removal element 16 can be constructed of acotton material but can be constructed of other materials. In variousembodiments, the removal element 16 can be constructed of materialswhich can allow for absorbing fluids or can be constructed of materialswhich do not allow for absorbing fluids. In various embodiments, theremoval element 16 can be a thread or ribbon made from 100% cottonfibers. In various embodiments, the removal element 16 can beconstructed of non-absorbent polyurethane, optionally with a coating ofsilicone film which can provide a smooth surface to the removal element16. In various embodiments, the removal element 16 can be a siliconecoated, braided polyester, an example of which is manufactured byAshaway.

In various embodiments, the removal element 16 of the vaginal insert 10can be from about 14 cm to about 16 cm in length, although the lengthcan be varied in different vaginal insert 10 configurations. In anembodiment, the removal element 16 can be secured to the cover 14 in aposition whereby a pulling force towards the vaginal introitus can besubstantially evenly distributed over the cover 14 as it collapses thesupporting arms 28 of the core 12 within the vagina. In an embodiment,this position can be in the center of the cover 14 in the supportingelement 20 region, such as illustrated in FIG. 1.

In various embodiments, the cover 14 can reduce friction between thevaginal insert 10 and the vaginal wall. Pulling the removal element 16can cause tensioning of the cover 14. Tensioning of the cover 14 canresult in the straightening of the vaginal walls which can therebyreduce the tent-like effect described above and relieve tension appliedto the vaginal insert 10, allowing for an easy and smooth removal of thevaginal insert 10 from the vagina. Furthermore, pulling on the removalelement 16 can cause the collapse of supporting arms 28 at leastslightly towards the longitudinal axis 24 as a result of the forceapplied to them by cover 14, thereby reducing the radial diameter of thecore 12 and allowing for an easy and smooth removal of the vaginalinsert 10 from the vagina.

Besides being used as an aide in removal of the vaginal insert 10, anadditional use of the cover 14 can be to act as a sling stretchedbetween supporting arms 28, which can supply sub-urethral tension-freesupport to the urethra.

Referring to FIGS. 10-12, perspective views of an applicator 40 whichcan be utilized to deploy a vaginal insert 10 for treating urinaryincontinence are illustrated. In an embodiment, the applicator 40 cancomprise a housing 42 and a plunger 44. The housing 42 can be adaptedfor receipt and/or storage of the vaginal insert 10. In variousexemplary embodiments, plunger 44 can be used to expel the vaginalinsert 10 from the housing 42 during vaginal insert 10 deployment into avagina. FIG. 11 is a cross-section of FIG. 10 which can show theconfiguration of applicator 40 more clearly, including the interfacebetween housing 42 and plunger 44. In various embodiments, housing 42can be provided with an outlet 46. In various embodiments, outlet 46 canbe provided with a plurality of flexible flaps (“petals”) which can bepushed open when vaginal insert 10 is expelled from applicator 40. Theoutlet 46 is more clearly shown in FIG. 12.

In the applicator 40, the vaginal insert 10 can be positioned such thatthe anchoring element 18 of the core 12 comes out of the applicator 40into the vagina first, followed by supporting element 20 of the core 12,which comes out at the end of the deployment process. In an embodiment,the vaginal insert 10 can be deployed to render support to the urethra.In an embodiment, the vaginal insert 10 can be deployed to rendersupport to the bladder neck.

In an embodiment, a user can receive the vaginal insert 10 in anindividual package 50 such as shown in FIG. 13. In an embodiment,different sizes and/or packages 50 with vaginal inserts 10 havingdifferent features can be color coded for ease of identification by auser of the vaginal insert 10. FIG. 13 is a side view of the componentparts of a product package 50 for a vaginal insert 10 for treatingurinary incontinence. Product package 50 can comprise an applicatorhousing 42, core 12, cover 14, removal element 16, applicator plunger44, and product wrapper 52. In an embodiment, product wrapper 52 can bewrapped around the applicator 40, which when packaged can include thevaginal insert 10 within the housing 42. Thus, product package 50 in itsassembled form can be more or less cylindrical or shaped like a wrappedtampon.

In an embodiment, insertion of the vaginal insert 10 into the vagina canbe similar to insertion of a tampon. The user can use one hand to spreadthe labia, direct the anterior part of the applicator 40 into thevagina, and compress the plunger 44 with the other hand, therebydeploying the vaginal insert 10 from the applicator 40 into the vagina.In an embodiment, there is no need for a specific orientation of thevaginal insert 10 because of the generally symmetrical design of thecore 12 about the longitudinal axis 24 of the core 12. The insertion ofthe vaginal insert 10 can be performed at any orientation and/oranywhere in the 360° around the longitudinal axis 24 of the core 12 inthe applicator 40.

In various embodiments, even though the core 12 can be designedsymmetrically, because each of the arms, 26 and 28, can flexindependently of the other arms, 26 and 28, when in situ and each vaginavaries in shape slightly, the vaginal insert 10 may not actually be insymmetrical form when in use (see FIG. 8). Referring to FIG. 8, a planview showing a possible relationship of the supporting arms 28 to thelongitudinal axis 24 of the core 12 when the vaginal insert 10 is insitu is illustrated. It is noted that not every vagina has the samecontours and internal structure, even though some generalizations can bemade about vaginal anatomical features. To that end, the core 12 can bedesigned to be adaptable to the varying vaginal features it may comeacross, depending on the user of the vaginal insert 10. For example,each of the supporting arms 28 of the core 12 can be capable offunctioning independently. This can enable maximal flexibility, maximaladjustment to any vaginal shape (cross section) and/or vaginaldimensions. Thus, it may happen that in a given cross section, thesupporting arms 28 of the core 12 will not be symmetrically spreadaround the longitudinal axis 24 of the core 12, such as shown in FIG. 8.

The core 12 can be manufactured and/or commercially available in aplurality of sizes, with each size exhibiting different performancecharacteristics, operational dimensions, weight and the like. In variousembodiments, differently sized cores 12 can be made of the samematerial. In various embodiments, differently sized cores 12 can usedifferent materials and/or different material ratios. FIGS. 14A-14C area series of charts illustrating exemplary core 12 sizes. As can be seenin the charts of FIGS. 14A-14C, core 12 can be produced in at least foursizes for optimal adjustment to various vaginal dimensions and/or inaccordance with the severity of urinary incontinence. The various sizescan differ in the diameter of the supporting arm's 28 spread and as aresult, can differ in the overall length when deployed (i.e., thesupporting arms 28 are spread). In various embodiments, the anchoringarms 26 can have identical deployed dimensions and/or performancecharacteristics in all of the sizes.

In various embodiments, core 12 can be constructed of liquid silicone(LSR) by injection molding. It is possible to use other materials, forexample TPE, non-liquid silicone, and others for a core 12 of the samesize. In an embodiment, materials exhibiting various degrees of Shore Ahardness can be used to produce softer or more rigid cores 12.

It should be understood that the various size combinations can be madeby varying the size and/or Shore A hardness. For example, sizes 1 and 2,could be made with a Shore A hardness of 70 while sizes 3 and 4 can havea Shore A hardness of 40. In various embodiments, all of the core 12sizes can exhibit the same Shore A hardness. In various embodiments,each individual size can be made in multiple versions, each exhibiting adifferent Shore A hardness. In sum, various combinations andpermutations of features, sizes, performance characteristics and/orconstruction materials can be employed to apply desired sub-urethralsupporting force at certain working angles.

In various embodiments, the radiating supporting arms 28 of core 12 cancreate an overall core 12 diameter from about 34 mm to about 52 mm atthe widest supporting element 20 cross section within the vaginalcavity. In various embodiments, the diameter can be larger or smallerdepending on the individual needs of the user.

FIG. 15 is a core 12 performance graph correlating expansive forceexerted by supporting arms 28 (y-axis) to amount of medial deflection(x-axis) and hardness (line hatchings) for each of the four basic sizesshown in FIGS. 14A-14C whereby medial deflection is the distance in mmtowards the longitudinal axis 24 of the core 12 from the naturalexpanded state of the supporting arm 28.

The expansive force exerted by the supporting arms 28 is generallydetermined by the hardness grade and/or the medial flexion degree(medial deflection) of each of the supporting arms 28 relative to thelongitudinal axis 24. If a specific material is used in construction ofthe core 12, such as, for example, liquid silicone, these forces can bemeasured for any given diameter of the supporting arms 28 of the core12, knowing the performance characteristics of the specific materialbeing used. Using this data in a graph where the x-axis represents thecore 12 diameter and the y-axis represents the force, the forces exertedby the supporting arms 28 for a given core 12 size and its materialhardness grade can be demonstrated. The slope represents the ratiobetween the force (grams) and the amount of medial deflection (mm).

In designing and/or selecting a core 12 for use, certain performanceconsiderations can be taken into account. It should be noted that core12 support is “activated” by the supporting arms 28 being compressed(i.e., deflected towards the longitudinal axis 24 of the core 12, or“medial deflection”) at least slightly by the vaginal wall. In general,the stronger the compressive forces on the supporting arms 28, thestronger the support force that is exerted back onto the vaginalwall/sub-urethra by the supporting arms 28. For example, supporting arms28 must be compressed a certain minimal amount in order to providecounterforce sufficient for the supporting arms 28 to render support.That is, if a vaginal insert 10 is inserted into a vagina and the core12 is too small or the angle of radial expansion is too small, then notenough force will be applied to the supporting arms 28 from the vaginalwall to cause the supporting arms 28 to counter with the force requiredto render appropriate and effective support. Failure to achieve thisminimal value of compression in an at-rest state, shown as a horizontalminimal applied force line 60 in FIG. 15 at approximately 10 g of force,on the supporting arms 28 during a stressful event will reduce vaginalinsert 10 efficacy. It should be noted that in some embodiments, theminimal applied force line 60 at 10 g is approximate and can vary ±3grams.

Similarly, there exists a maximum force exerted by the core 12 on thevaginal walls beyond which the user would experience discomfort whilethe vaginal insert 10 is in the vagina at-rest and/or while removing thevaginal insert 10. In an embodiment, therefore, the core 12 can bedesigned and/or selected for use not to exceed this maximal force. Thismaximal force is represented in FIG. 15 as the bold horizontal line 62at approximately 50 g of force. In an embodiment, 50 grams isapproximate and can vary ±5 grams. For example, if the radial expansionof the supporting arms 28 is too great, it will generate excessive forceon the vaginal wall and the user may experience discomfort, which is tobe avoided.

The graph of FIG. 15 can be used, in various embodiments, to determinethe use potential for a specific core 12 configuration for a specificvaginal size. For example, D1 on the graph represents a vagina with adiameter of 33 mm. Referring to FIG. 15, it can be seen that size 1cores 12 with Shore A hardnesses of S40 and S50 are not indicated foruse with this user because they will not provide sufficiently effectivesupport in an at-rest state. However, a number of other core 12 sizesand Shore A hardnesses are considered acceptable:

-   -   Size 1 with Shore A hardness of 70 device (supplying force of        about 21 grams)    -   Size 2 with Shore A hardness of 50 device (supplying force of        about 25 grams)    -   Size 2 with Shore A hardness of 40 device (supplying force of        about 20 grams)    -   Size 3 with Shore A hardness of 50 device (supplying force of        about 38 grams)    -   Size 3 with Shore A hardness of 40 device (supplying force of        about 28 grams)    -   Size 4 with Shore A hardness of 50 device (supplying force of        about 48 grams)    -   Size 4 with Shore A hardness of 40 device (supplying force of        about 35 grams)

As another example, D2 on the graph represents a vagina with a diameterof 42.5 mm. Because of the size of this user's vagina, fewer choices maybe available for receiving ideally efficacious vaginal support. In thisexample, likely choices would include:

-   -   Size 3 with Shore A hardness of 70 device (supplying force of        about 22 grams)    -   Size 4 with Shore A hardness of 70 device (supplying force of        about 45 grams)    -   Size 4 with Shore A hardness of 50 device (supplying force of        about 22 grams)    -   Size 4 with Shore A hardness of 40 device (supplying force of a        bout 18 grams)

It is noted that a size 4 core 12 made of a low Shore A hardnessmaterial, for example 40, can be used for a wide variety of vaginaldiameters (approximately 30 mm to 45 mm), in an exemplary embodiment.

Above the maximum force line 62, the graph of FIG. 15 shows forceexertion levels of the various core 12 sizes at different levels ofmedial deflection all the way down to about 12 mm in total core 12diameter. In an embodiment, each arm is approximately 6 mm in width,therefore the minimum diameter distance possible is when two opposingarms have come into contact or 12 mm (6 mm+6 mm). Specific numbers forselected core 12 sizes are shown in and described in more detail belowwith respect to FIG. 16.

FIG. 16 is a table showing specific performance levels for exemplarybasic core 12 sizes and Shore A hardnesses depicted in FIG. 15. Theminimal diameter column lists the diameter (in mm) at which two opposingarms 28 come into contact thereby substantially prohibiting any furthermedial deflection by the arms 28. In an embodiment, maximal force isexerted when the cores 12 are compressed the most, or at the minimaldiameter. The max force column lists the maximum amount of force exertedby each listed core 12 size and Shore A hardness at the 12 mm diameterlevel.

It is noted that some of the information shown in FIG. 16 is alsoincluded in the tables of FIGS. 14A-14C. Where the information is notentirely in conformance, it should be understood that the broadest rangeof values is to be attributed to the embodiments described herein. Forexample, a range of values may be taken where the low end of the rangeis from one table and the high end of the range is from another table.It should also be noted that values given are by way of example only,and that core 12 performance characteristics can vary depending onmaterials used for construction and/or core 12 size and/or Shore Ahardness.

In various embodiments, many of the possible sizes of cores 12 can besuitable for a particular user and sufficient support can be providedwithout surpassing the discomfort threshold. This can be particularlytrue with cores 12 of low Shore A hardness and moderate slope. Forexample, a core 12 of size 3 (support diameter—45 mm) made of softsilicone with a Shore A hardness of 40 may be suitable for a broad rangeof vaginal diameters: exerting a force of 12 grams over a diameter of 40mm, 21 grams over a diameter of 35 mm, and 31 grams over a diameter of30 mm. In other words, in some embodiments, a single core 12 size canprovide support to numerous vaginal dimensions. In an embodiment, a core12 can be adapted to be usable by a variety of users, for example bydesigning a core 12 with a low or moderate slope.

It is possible that only one size of core 12 will be suitable for awoman with a certain vaginal diameter, especially if her vaginaldimensions are larger than the average. In some embodiments, only sizes3 or 4 would be suitable, while the smaller sizes would not exert theminimal support force required. It should be noted that characteristicssuch as the force applied, the size of the vaginal insert 10 and/oroverall comfort of the vaginal insert 10 chosen is highly dependent oneach individual user and may also depend on the pathological responsecaused by the vaginal insert 10 for each individual user.

In an exemplary embodiment, reducing the distance between the supportingtip 32 of a supporting arm 28 and the longitudinal axis 24 of the core12 would increase the force exerted by the core 12 at the supporting tip32. The operative significance of this can be that a relatively largevaginal insert 10 inserted into the vagina would exert a higher force onthe vaginal walls as compared to a smaller vaginal insert 10 insertedinto the same vagina. Using this same rationale, if external forcesexerted on the vaginal insert 10 reduce the internal distance betweenits supporting arms 28 and the longitudinal axis 24 (e.g. duringcoughing, jumping, sneezing, etc.), a greater counteracting force wouldbe exerted by the supporting arms 28 on the vaginal walls, thusenhancing the urethral support and the efficiency of urinary leakprevention. Therefore, in an exemplary embodiment, a vaginal insert 10can be designed with this activity-generated counter tension in mind.

Vaginal Insert Method of Manufacture:

As described above, in an embodiment, a vaginal insert 10 can have acore 12, a cover 14, and a removal element 16. The manufacturing processto produce a vaginal insert 10 can include steps such as providing acover blank 68, enclosing a core 12 within the cover blank 68, andproviding a removal element 16. In various embodiments, themanufacturing process can also include a step of conforming the cover 14to the core 12.

For the vaginal insert 10 to be efficacious in reducing episodes ofleakage due to urinary incontinence, the vaginal insert 10 needs to besmall enough for insertion into and removal from the vagina, but alsoneeds to be able to radially expand following insertion and during wear.The core 12 of the vaginal insert 10, therefore, should be capable oftransitioning between a compressed configuration and a radially expandedconfiguration. To avoid restricting this transition betweenconfigurations, the cover 14 should be sized large enough to allow thecore 12 to expand to its largest required dimension during wear. Whilethe cover 14 should be large enough to allow expansion of the core 12,the cover 14 should also be sized correctly to assist in the removal ofthe vaginal insert 10. As described herein, pulling on the removalelement 16 can result in a pulling force being substantially evenlydistributed over the cover 14 which can work to collapse the supportingarms 28 of the core 12 towards the longitudinal axis 24 of the core 12,thereby reducing the radial diameter of the core 12 and allowing for asmooth and easy removal of the vaginal insert 10 from the vagina. Thecover 14, therefore, should not be sized so large that the cover 14 haslittle effect on the supporting arms 28 of the core 12 when pulling onthe removal element 16 during removal of the vaginal insert 10.

In an embodiment, the cover 14 can conform to the shape and/or size ofthe core 12. As mentioned above, in various embodiments, the cover 14can act as a sling stretched between arms, such as the supporting arms28, of the core 12. In such embodiments, the cover 14 can supplysub-urethral tension free support to the urethra. Also as describedherein, the core 12 can transition from a compressed configuration to aradially expanded configuration to provide support to the urethra. Thecover 14 can be conformed to the size and/or shape of the core 12 inorder to provide the cover 14 with the tension needed to allow the cover14 to adequately act as a sling and support the urethra. Without beingbound by theory, it is believed that a cover 14 that is not conformed tothe size and/or shape of the core 12, or has not been adequatelyconformed to the size and/or shape of the core 12, will be too loose asan enclosure to the core 12 and will not provide adequate support to theurethra. As mentioned above, the cover 14, however, should not be overlyconformed to the size and/or shape of the core 12 as that could preventthe core 12 from radially expanding to the extent necessary to provideadequate support to the urethra. In various embodiments, the cover 14can be conformed to the core 12 via a process which can reduce thedimensions of the cover 14 and maintain the reduced dimensions of thecover 14. In various embodiments, the cover 14 can be conformed to thecore 12 via a process which can reduce the dimensions of the cover 14 atthe narrowest portion of the core 12, such as, for example, the node 22.In various embodiments, the dimensions of the cover 14 can be reducedvia processes such as, but not limited to, wrapping a band of materialaround the cover 14 to “tighten” the cover 14, twisting the materialforming the cover 14, applying a thermal treatment to the cover 14 suchas a cover 14 formed of a heat-shrinkable material, and/or altering theelastic and/or extensible properties of the cover 14. In an embodiment,the cover 14 shape and/or dimensions can be substantially similar to theexpanded shape and/or dimensions of the core 12. In an embodiment, theinternal volume of the cover 14 can be substantially similar to thevolume of the expanded core 12.

A cover 14 can be formed from a cover blank 68. A cover blank 68 can becreated via at least one of two methods. A first method of creating acover blank 68 can include folding a single material in half, bringingthe two halves together in a face-to-face relationship, and bonding atleast a portion of the two halves together to create at least one bondarea. A second method to create a cover blank 68 can include providingtwo separate materials together in a face-to-face relationship andbonding at least a portion of the two separate materials together tocreate at least one bond area. The at least one bond area, resultingfrom either method just described, can ultimately provide at least oneseam for a cover 14. In various embodiments, a cover blank 68 can haveat least one bond area. In various embodiments, a cover blank 68 canhave at least two bond areas. In various embodiments, a cover blank 68can have at least three bond areas. Once the cover blank 68 fullyencloses a core 12 and the material forming the cover blank 68 has beenfully seamed together to prevent the core 12 from escaping the confinesof the cover blank 68, the cover blank 68 can be said to have beenconverted to a cover 14. In various embodiments, the cover 14 can haveat least one seam. In various embodiments, the cover 14 can have atleast two seams. In various embodiments, the cover 12 can have at leastthree seams. In various embodiments, the cover 12 can have at least fourseams.

The terms “bonded” and “bonding” refer herein to the joining, adhering,connecting, attaching, or the like, of two elements. Two elements willbe considered bonded together when they are joined, adhered, connected,attached, or the like, directly to one another or indirectly to oneanother, such as when each is directly bonded to intermediate elements.The bonding can occur via adhesive, pressure bonding, thermal bonding,ultrasonic bonding, stitching, suturing, and/or welding.

FIG. 17 provides an exemplary illustration of a method to manufacture acover blank 68. As illustrated in FIG. 17, a single material 90 can beutilized. The material 90, in an unfolded configuration, can have twoopposing and spaced apart machine-directions edges, such as edges 92 and94. The material 90 can enter a folding zone 96 wherein the material 90can be folded such that two halves of the material 90 can be createdwith one half brought into a face-to-face relationship with the otherhalf of material 90. The folding of material 90 can be accomplishedthrough the use of, for example, a folding board. The folding ofmaterial 90 can bring edge 94 into a position substantially adjacent toedge 92. The resulting fold 98 in the material 90 can remain parallel toand spaced apart from the edges, 92 and 94, and the fold 98 and theedges, 92 and 94, can continue to move in the machine direction. Thefolded material 90 can continue to a bonding zone 100 wherein at least aportion of one of the halves of the folded material 90 can be bonded toat least a portion of the other half of the folded material 90. Thebonding can be accomplished by methods such as, but not limited to,adhesive, pressure bonding, thermal bonding, ultrasonic bonding,stitching, suturing, and/or welding.

The bonding of at least a portion of the two halves of folded material90, or, in various embodiments, the bonding together of at least aportion of two separate materials, can form at least one bond area. Theat least one bond area can ultimately provide at least one seam of acover 14. A bond area can have a width as deemed suitable to maintainthe integrity of the bond area, and resultant seam of the cover 14. Invarious embodiments, a bond area can have a width from about 0.1, 0.2,0.3, 0.4, or 0.5 mm to about 0.6, 0.7, 0.8, 0.9 or 1.0 mm.

Referring to FIG. 17, in the exemplary embodiment of the methodillustrated, two bond areas, 84 and 86, can be created. As the bondareas, such as bond areas 84 and 86, can ultimately provide a seam forthe cover 14, the bond areas, 84 and 86, can provide a portion of theshape of the cover blank 68. In various embodiments, the cover blank 68can have a rectangular, trapezoidal, or trapezoid-like shape when viewedin a flat, two-dimensional configuration. A trapezoid-like shape canhave at least two parallel sides and the other two sides can benon-parallel, can have an arc, or can have any other shape as desired.As can be seen in the exemplary illustration of FIG. 17, the bond areas,84 and 86, which have been formed can provide for a cover blank 68 whichcan have a trapezoidal shape when viewed in a flat, two-dimensionalconfiguration.

In various embodiments, the desired maximum width of the cover blank 68,in a flat, two-dimensional configuration, at its widest dimension, canbe narrower than the width of the material(s) 90 provided and bondedtogether to form the cover blank 68. In such various embodiments, anarea of trim material can be located between the bond areas, such asbond areas 84 and 86, and the edges and/or fold of the material 90utilized to make the cover blank 68. In the exemplary embodimentillustrated in FIG. 17, the bond areas, 84 and 86, can be locatedinterior to the edges, 92 and 94, and the fold 98 of the material 90.Areas of trim 102, therefore, can be located between the bond areas, 84and 86, and the edges, 92 and 94, and the fold 98 of the material 90. Asthe material 90 can be further processed into a cover blank 68, theareas of trim 102 can be separated from the bond areas, 84 and 86, astrim waste 110. The removal of the trim waste 110 will be discussedherein below.

The material 90 can enter a perforation zone 104 wherein perforations106 can be imposed upon the material 90. The perforations 106 can becreated through the use of any perforation cutter deemed suitable. Theperforations 106 can be a perforations 106 extending across the material90 in the cross-machine direction. The perforations 106 can provide aseparation between ultimately two cover blanks 68. In variousembodiments, the perforations 106 may not extend into the areas of trim102 located between the bond areas, 84 and 86, and the edges, 92 and 94,and the fold 98 of the material 90. In various embodiments, withoutbeing bound by theory, it is believed that not extending theperforations 106 into the areas of trim 102 can enable efficient removalof the areas of trim 102 during the manufacturing process.

To remove the areas of trim 102, the material 90 can enter a trimremoval zone 108 wherein a slitter can be used to separate the areas oftrim 102, as trim waste 110, from the material 90. The trim waste 110can be pulled away from the material 90 via any method deemed suitable,such as a vacuum. After the areas of trim 102 have been removed, as trimwaste 110, the bond areas 84 and 86, can become seams, such as sideseams 72 and 74, of a cover blank 68.

It should be noted that, in various embodiments, the machine-directionlength of material(s) 90 provided to manufacture a cover blank 68 can besufficient to manufacture a single cover blank 68 or, in variousembodiments, the machine-direction length of the material(s) 90 providedcan be sufficient to manufacture multiple cover blanks 68 such as, forexample, a ribbon 112 of cover blanks 68 manufactured in a sequentialmanner. FIGS. 17 and 18 provide exemplary illustrations of a ribbon 112of cover blanks 68. FIG. 17 can provide an illustration of a ribbon 112of cover blanks pre- and post-separation of the areas of trim 102. FIG.18 can provide an illustration of a ribbon 112 of cover blanks 68pre-separation of the areas of trim 102.

Referring to FIG. 18, an exemplary embodiment of a portion of a ribbon112 of cover blanks 68 can be illustrated. In FIG. 18, two separatematerials 90 can be brought in a face-to-face relationship. Each of thematerials 90 can have parallel and spaced apart edges, such as edges 92and 94, extending in the machine-direction. At least a portion of thetwo separate materials 90 can be bonded together and bond areas, 84 and86, can be created. Areas of trim 102 can be located between the bondareas, 84 and 86, and the edges, 92 and 94, of the materials 90. As canbe seen in the exemplary embodiment of FIG. 18, the width W3 of thematerials 90 forming the cover blank 68 can be larger than the widestwidth of the cover blank 68, such as width W2 of the cover blank 68.

As illustrated in the exemplary embodiments of FIG. 17 and FIG. 18, theribbon 112 of cover blanks 68 illustrates that the largest width W2 of afirst cover blank 68 is sequentially adjacent to the largest width W2 ofthe next cover blank 68 and the narrowest width W1 of a first coverblank 68 is sequentially adjacent to the narrowest width W1 of the nextcover blank 68. Without being bound by theory, it is believed thatmaintaining the narrowest widths W1 of two cover blanks 68 in anadjacent relationship as well as maintaining the widest widths W2 of twocover blanks 68 in an adjacent relationship can provide for a moreefficient incorporation of the perforation 106 between cover blanks 68as well as for a more efficient removal of the areas of trim 102 as trimwaste 110.

In a manufacturing process for sequential manufacture of cover blanks68, a connected ribbon 112 of cover blanks 68 can be present prior tothe separation of the areas of trim 102 as trim waste 110 such asillustrated in FIG. 18. In a manufacturing process for sequentialmanufacture of cover blanks 68, a connected ribbon 112 of cover blanks68 can be present post separation of the areas of trim 102 as trim waste110, such as illustrated in FIG. 17. A single cover blank 68 can beseparated from the connected ribbon 112 of cover blanks 68 by breakingthe perforations 106 between two adjacent cover blanks 68.

FIGS. 19 and 20 provide exemplary illustrations of cover blanks 68 inflat, two-dimensional configurations, which can be separated from aribbon 112 of cover blanks 68. As the cover blank 68 can be manufacturedfrom a single material 90 folded over onto itself or from two materials90 brought together in a face-to-face relationship, the cover blank 68,70 and 80, of material 90 with one layer, such as layer 70, overlayingthe other layer, such as layer 80. In the exemplary embodimentsillustrated in FIGS. 19 and 20, layer 70 is facing the viewer. The coverblank 68 can have bonded side seams, such as side seams 72 and 74. Thecover blank 68 can have top edges 76 of each layer, 70 and 80, which arenot bonded to each other. The cover blank 68 can have bottom edges 78 ofeach layer, 70 and 80, which are not bonded to each other. In variousembodiments, when viewed in a flat, two-dimensional configuration, thecover blank 68 can have the rectangular configuration as illustrated inthe exemplary embodiment of FIG. 19. In various embodiments, when viewedin a flat, two-dimensional configuration, the cover blank 68 can havethe trapezoidal configuration as illustrated in the exemplary embodimentof FIG. 20. In various embodiments, when viewed in a flat,two-dimensional configuration, a cover blank 68 can have atrapezoid-like configuration. In various embodiments, when viewed in aflat, two-dimensional configuration, the cover blank 68 can have anyother configuration as deemed suitable to provide a cover 14 forenclosing a core 12.

During the manufacturing process, the top edges 76 of each layer, 70 and80, and the bottom edges 78, of each layer, 70 and 80, can be bondedtogether to ultimately form the cover 14 for a core 12 of a vaginalinsert 10. The bottom edges 78 of each layer, 70 and 80, when bondedtogether can form a bonded area 168 which can be located near thesupporting element 20 of the core 12. The top edges 76 of each layer, 70and 80, when bonded together can form a bonded area 318 which can belocated near the anchoring element 18 of the core 12.

In various embodiments, when viewed in a flat, two-dimensionalconfiguration, a cover blank 68 can have a rectangular configurationsuch as illustrated in FIG. 19. The cover blank 68 can have an initiallongitudinal length L1, measured as the distance from the top edge 76 tothe bottom edge 78 of the layers, 70 and 80. Each of the edges, top edge76 and bottom edge 78, of the respective layers, 70 and 80, can have aninitial top edge width W1 and an initial bottom edge width W2,respectively. In an embodiment, such as illustrated in FIG. 19, in whichthe cover blank 68 can have a rectangular configuration, the initial topedge width W1 and the initial bottom edge width W2 can be the same.

In an embodiment, the core 12 can be symmetrical about the longitudinalaxis 24 of the core 12 as well as symmetrical about the lateral axis ofthe core 12 wherein the lateral axis of the core 12 can be located atthe midpoint of the longitudinal axis 24 of the core 12. Thesesymmetries can be present when the core 12 can be in a compressedconfiguration and when the core 12 can be in a radially expandedconfiguration. In such an embodiment, a cover blank 68 can be providedwhich can be symmetrical and/or can assume symmetry about thelongitudinal axis 82 of the cover blank 68 as well as can be symmetricaland/or can assume symmetry about the lateral axis of the cover blank 68wherein the lateral axis of the cover blank 68 can be located at themidpoint of the longitudinal axis 82 of the cover blank 68. Thesesymmetries of the cover blank 68 can be visible when the cover blank 68can be viewed in a flat, two-dimensional configuration, such as prior tothe enclosure of a core 12 within the cover blank 68. FIG. 19 providesan illustration of a cover blank 68 in a flat, two-dimensionalconfiguration and the cover blank 68 can have a symmetricalconfiguration around both the longitudinal axis 82 of the cover blank 68and about the lateral axis located at the midpoint of the longitudinalaxis 82 of the cover blank 68.

In various embodiments, when viewed in a flat, two-dimensionalconfiguration, a cover blank 68 can have a trapezoidal configurationsuch as illustrated in FIG. 20. The cover blank 68 can have an initiallongitudinal length L1, measured as the distance from the top edge 76 tothe bottom edge 78 of the layers, 70 and 80. Each of the edges, top edge76 and bottom edge 78, of the respective layers, 70 and 80, can have aninitial top edge width W1 and an initial bottom edge width W2,respectively. In an embodiment, such as illustrated in FIG. 20 in whichthe cover blank 68 can have a trapezoidal configuration, the initial topedge width W1 may not be the same as the initial bottom edge width W2.In such an embodiment, the top edge width W1 can be smaller than thebottom edge width W2.

In an embodiment, the core 12 can be symmetrical about the longitudinalaxis 24 of the core 12, however, the core 12 may not be symmetricalabout the lateral axis of the core 12 wherein the lateral axis of thecore 12 can be located at the midpoint of the longitudinal axis 24 ofthe core 12. The symmetry of the core 12 about the longitudinal axis 24of the core 12 can be present when the core 12 can be in a compressedconfiguration and when the core 12 can be in a radially expandedconfiguration. In such an embodiment, a cover blank 68 can be providedwhich can be symmetrical and/or can assume symmetry about thelongitudinal axis 82 of the cover blank 68. The symmetry of the coverblank 68 about the longitudinal axis 82 of the cover blank 68 can bevisible when the cover blank 68 can be viewed in a flat, two-dimensionalconfiguration, such as prior to the enclosure of a core 12 within thecover blank 68. FIG. 20 provides an illustration of a cover blank 68 ina flat, two-dimensional configuration and the cover blank 68 can besymmetrical about the longitudinal axis 82 of the cover blank 68 but maynot be symmetrical about the lateral axis located at the midpoint of thelongitudinal axis 82 of the cover blank 68.

As described herein, FIG. 14 provides exemplary core 12 configurationswhen the core 12 can be in a deployed/radially expanded configuration.The cover blank 68 can be appropriately sized to enclose a core 12 suchas described herein. It should be noted that as the core 12 can beprovided in various sizes, the cover blank 68 can also be provided invarious initial sizes to conform to the size of the core 12. In variousembodiments, the cover blank 68, in a flat, two-dimensionalconfiguration, and prior to the enclosure of a core 12, can have aninitial longitudinal length L1 from about 90, 92, 94, 96, 98, 99 or 100mm to about 101, 102, 104, 106, 108, or 110 mm. In an embodiment, thecover blank 68, in a flat, two-dimensional configuration, and prior tothe enclosure of a core 12, can have an initial longitudinal length L1of about 100 mm±1 mm. In various embodiments, the cover blank 68, in aflat, two-dimensional configuration, and prior to the enclosure of acore 12, can have an initial top edge width W1 and a bottom edge widthW2 from about 40, 42, 44, 46, 48, 50, 52, 54, 56, 58 or 60 mm to about70, 72, 74, 76, 78, 80, 82, 84, 86, 88 or 90 mm. In an embodiment, thecover blank 68, in a flat, two-dimensional configuration can berectangular in shape and the top edge width W1 can be the same as thebottom edge width W2. In an embodiment, the cover blank 68, in a flat,two-dimensional configuration can have a shape such as a trapezoidalshape, and the top edge width W1 can be different than, such as, forexample, smaller than, the bottom edge width W2.

As an illustrative example of a core 12 and cover blank 68 combination,a core 12 can have an anchoring element 18, a supporting element 20, anda node 22 located between the anchoring element 18 and the supportingelement 20. In the deployed/radially expanded configuration, theanchoring element 18 of the core 12 can have a radial diameter of about32 mm±1 mm, the supporting element 20 can have a radial diameter ofabout 41 mm±1 mm, and the length of the core 12 can be about 42 mm±1 mm.The cover blank 68 for such a core 12, can have a trapezoidalconfiguration and can have the following initial dimensions when viewedin a flat, two-dimensional configuration, and prior to the enclosure ofthe core 12: a longitudinal length L1 of about 100 mm±1 mm, a top edgewidth W1 of about 50 mm±1 mm, and a bottom edge width W2 of about 61mm±1 mm.

As another illustrative example of a core 12 and cover blank 68combination, a core 12 can have an anchoring element 18, a supportingelement 20, and a node 22 located between the anchoring element 18 andthe supporting element 20. In the deployed/radially expandedconfiguration, the anchoring element 18 of the core 12 can have a radialdiameter of about 32 mm±1 mm, the supporting element 20 can have aradial diameter of about 50 mm±1 mm, and the length of the core 12 canbe about 37 mm±1 mm. The cover blank 68 for such a core 12, can have atrapezoidal configuration and can have the following initial dimensionswhen viewed in a flat, two-dimensional configuration, and prior to theenclosure of the core 12: a longitudinal length L1 of about 100 mm±1 mm,a top edge width W1 of about 50 mm±1 mm, and a bottom edge width W2 ofabout 80 mm±1 mm.

It is to be understood that as the cover blank 68 undergoes theprocessing steps described herein, the size dimensions of the coverblank 68 can change, such as, for example, become smaller than theinitial dimensions of the cover blank 68. For example, the cover blank68 may have initial size dimensions, such as an initial longitudinallength L1. As the cover blank 68 is further processed, such as, forexample, at least one edge, such as top edge 76, of layers 70 and 80being bonded together and/or the removal of trim waste, the resultantlongitudinal length of the cover blank 68 at the time of insertion ofthe core 12 within the cover blank 68, enclosure of the core 12 withinthe cover blank 68, and/or final seaming of the cover blank 68 may besmaller than the initial longitudinal length L1.

During the manufacturing process the cover 14 can be manipulated toassume the desired configuration dependent upon the desiredconfiguration of the core 12. The cover 14, therefore, can be conformedto the core 12. As described herein, the core 12 can have a node 22located between the anchoring element 18 and the supporting element 20.In an embodiment in which the core 12 is symmetrical about both thelongitudinal axis 24 of the core 12 and the lateral axis located at themidpoint of the longitudinal axis 24 of the core 12, the node 22 can belocated at the midpoint of the longitudinal axis 24 of the core 12. Inan embodiment in which the core 12 is symmetrical about the longitudinalaxis 24 of the core but not symmetrical about the lateral axis locatedat the midpoint of the longitudinal axis 24 of the core 12, the node 22may not be located at the midpoint of the longitudinal axis 24 of thecore 12. In such an embodiment, the supporting arms 28 can be longerthan the anchoring arms 26 and the node 22 can be closer to theanchoring tips 30 of the core 12 and further from the supporting tips 32of the core 12. In either embodiment, the cover 14 can be conformed tothe desired configuration of the core 12 by cinching the cover 14 in thearea where the node 22 of the core 12 is located.

To enclose a core 12 within the cover blank 68, the cover blank 68 canbe converted from a flat, two-dimensional configuration to athree-dimensional configuration to provide a space between the twolayers, 70 and 80, of material 90 of the cover blank 68 within which toinsert the core 12. The process of converting the cover blank 68 from atwo-dimensional configuration to a three-dimensional configuration caninclude loading the cover blank 68 onto a first pallet which can haveprongs, 124 and 126, to open the cover blank 68. An exemplary embodimentof a first pallet 120 which can have prongs, 124 and 126, can beillustrated in FIGS. 21-23.

FIG. 21 provides an illustrative example of a front view of a portion ofa first pallet 120 with a base 122 and a location 118 whereupon a coverblank 68 can be loaded. FIG. 22 provides a top view of a first pallet120 with at least a location 118 whereupon a cover blank 68 can beloaded. FIG. 23 provides a side view of a first pallet 120 with alocation 118 whereupon a cover blank 68 can be loaded. It is to be notedthat the first pallet 120 can have as many locations 118 as are desiredfor loading cover blanks 68 for conversion from a two-dimensionalconfiguration to a three-dimensional configuration. In variousembodiments, the first pallet 120 can have at least 1, 2, 3, 4, 5, 6, 7,8, 9, or 10 locations 118 for receiving a two-dimensional cover blank 68for conversion to a three-dimensional cover blank 68. In variousembodiments, a first pallet 120 can have from about 1, 2, 3, 4 or 5locations 118 to about 6, 7, 8, 9 or 10 locations 118.

Referring to FIGS. 21-23, each location 118 on a first pallet 120 canhave a pair of mounting brackets, such as mounting brackets 128 and 130.Each of the mounting brackets, 128 and 130, can be manufactured from anymaterial deemed suitable such as, but not limited to, steel, aluminum,plastic, etc. The mounting brackets, 128 and 130, can have the abilityto transition from a closed configuration (illustrated in FIG. 22) to anopen configuration (illustrated in FIG. 23). The mounting brackets, 128and 130, can be hingedly connected with each other such that themovement of one mounting bracket, such as mounting bracket 128, cancause movement of the other mounting bracket, such as mounting bracket130. For example, causing mounting bracket 128 to transition from aclosed configuration to an open configuration, such as, for example, bypressing on the base of mounting bracket 128, can result in mountingbracket 130 completing the same transition. Each mounting bracket, 128and 130, can be operatively connected with the first pallet 120 in anymanner deemed suitable to enable the transition from a closedconfiguration to an open configuration such as, for example, through theuse of a hinge. Each mounting bracket, 128 and 130, can have, on itsrespective inward-facing side, a hemispherical shape, such that when thetwo mounting brackets, 128 and 130, can be brought together in a closedconfiguration, such as illustrated in FIG. 22, the two hemispheres canform a complete circle around an open area 132. Each of the mountingbrackets, 128 and 130, can have a height H1 which can be any heightdeemed suitable for the manufacturing process described herein.

Referring to FIGS. 21-23, each mounting bracket, 128 and 130, can beassociated with a pair of prongs, 124 and 126. For example, mountingbracket 128 can be associated with a pair of prongs 124 and mountingbracket 130 can be associated with a pair of prongs 126. The pairs ofprongs, 124 and 126, can each have a base portion which can beassociated with the inward-facing side of each mounting bracket, 128 and130, respectively. The base portion of each pair of prongs, 124 and 126,can be associated with its respective mounting bracket, 128 and 130,through any manner deemed suitable, such as, for example, welding or theuse of screws. Each pair of prongs, 124 and 126, can each have a portionwhich can extend beyond the height H1 of the mounting brackets, 128 and130, such that the cover blank 68 can be mounted onto the portions ofthe pairs of prongs, 124 and 126, which extend beyond the mountingbrackets, 128 and 130.

In various embodiments, each pair of prongs, such as prongs 124, can betwo separate components associated with the same respective mountingbracket, such as mounting bracket 128. In such embodiments, eachlocation 118 on first pallet 120 can have two mounting brackets, 128 and130, and four individual prongs each having its own base associated withits respective mounting bracket, 128 and 130 (e.g., two individualprongs 124, each prong 124 associated with mounting bracket 128 and twoindividual prongs 126, each prong 126 associated with mounting bracket130). In various embodiments, each pair of prongs, such as prongs 124,can be manufactured from a single material and shaped into aconfiguration such that the two prongs, such as prongs 124, extend fromthe same base of material. In such embodiments, each location 118 onfirst pallet 120 can have two mounting brackets, 128 and 130, and fourindividual prongs wherein two prongs 124 extend from a single commonbase associated with mounting bracket 128 and two prongs 126 extend froma single common base associated with mounting bracket 130.

As described above, the mounting brackets, 128 and 130, can each have ahemispherical shape on their inward-facing sides such that when themounting brackets, 128 and 130, are in a closed configuration thehemispherical shapes can form a complete circle surrounding an open area132. The base material of the prongs, 124 and 126, can be configuredsuch that they follow the same curvature of the mounting brackets, 128and 130. It is to be noted that the inward-facing side of the mountingbrackets, 128 and 130, need not be a hemispherical shape to form acomplete circle and an open area 132. The open area 132 can allow forthe passage of various rods, such as push rods, and/or pre-tuck bars,through the pallets (first, second, and third pallets described herein).The open area within each of the pallets can be any shape deemedsuitable to allow the passage of the various rods. In variousembodiments, the open area can be circular, square, overall, andrectangle, etc. The shape of the open area can be defined by the pallet,such as, for example, the shape of open area 132 can be defined by theinward-facing side of the mounting brackets, 128 and 130.

The prongs, 124 and 126, can be manufactured from any material deemedsuitable, such as, but not limited to, steel, plastic, aluminum, etc.The prongs, 124 and 126, can have any shape and configuration as deemedsuitable which can allow the prongs, 124 and 126, to open and close andto hold the cover blank 68 during the conversion from a flat,two-dimensional cover blank 68 to a three-dimensional cover blank 68 andduring the provision of an additional seam to the cover blank 68. Duringthis process, the prongs, 124 and 126, should not impede any otheractivity or process step in the manufacturing process. In variousembodiments, the prongs, 124 and 126, can be mirror images of eachother. The prongs, 124 and 126, can each have a height H2 extendingbeyond the mounting brackets, 128 and 130. The height H2 of the prongs,124 and 126, can be less than the overall initial longitudinal length L1of the cover blank 68 such that the prongs, 124 and 126, may notinterfere with further processing of the cover blank 68, such as, forexample, the bonding of the bottom edges 78 of layers 70 and 80 of thecover blank 68.

As noted above, the mounting brackets, 128 and 130, can transition froma closed configuration, such as in FIG. 22, to an open configuration,such as in FIG. 23. As the prongs, 124 and 126, can each have a baseassociated with the mounting brackets, 128 and 130, the prongs, 124 and126, can undergo the same transition in configuration (i.e., from aclosed configuration to an open configuration). Referring to FIG. 22,the mounting brackets, 128 and 130, can be in a closed configuration.The bases of the prongs, 124 and 126, can be associated with themounting brackets, 128 and 130, in such a way as to enable the portionof the prongs, 124 and 126, extending beyond the mounting brackets, 128and 130, to be in close proximity with each other when the mountingbrackets, 128 and 130, are in a closed configuration. In variousembodiments, the prongs 124 and 126 can contact each other (e.g, a prong124 contacting a prong 126) when the mounting brackets, 128 and 130, arein a closed configuration. Referring to FIG. 23, when the mountingbrackets, 128 and 130, have transitioned to an open configuration, theportion of the prongs, 124 and 126, extending beyond the mountingbrackets, 128 and 130, can also transition to an open configuration andthe prongs, 124 and 126, can move directionally away from each other.This movement of the prongs, 124 and 126, away from each other can causethe cover blank 68 to convert from a flat, two-dimensional configurationto an open, three-dimensional configuration as the movement of theprongs, 124 and 126, away from each other can force the layers, 70 and80, of the cover blank 68 away from each other.

As described above, in various embodiments, a ribbon 112 of cover blanks68 can be manufactured. In various embodiments, such as the embodimentillustrated in FIG. 18, the cover blanks 68 in a ribbon 112 of coverblanks 68 can have a trapezoidal configuration and the top edges 76 oflayers 70 and 80 of two cover blanks 68 can be adjacent each other andthe bottom edges 78 of layers 70 and 80 of two cover blanks 68 can beadjacent each other. As described above, it is believed this arrangementcan provide for better efficiency in the removal of areas of trim 102 astrim waste 110. In order to convert each individual cover blank 68 froma two-dimensional configuration to a three-dimensional configuration, anindividual cover blank 68 can be separated from the ribbon 112 of coverblanks 68 and loaded onto a first pallet 120 at a location 118 havingprongs, 124 and 126.

In various embodiments, it may be desirable to bond the bottom edges 78of layers 70 and 80 of the cover blank 68 following the loading of thecover blank 68 onto the first pallet 120. Bonding of the bottom edges 78of layers 70 and 80 of the cover blank 68 can form a bond area 168 whichcan ultimately form a seam, such as supporting element seam 174, whichcan be located near the supporting element 20 of a core 12. In suchembodiments, the cover blank 68 can be loaded onto the first pallet 120such that the top edges 76 of layers 70 and 80 of the cover blank 68 areclosest to the mounting brackets, 128 and 130, and the bottom edges 78of layer 70 and 80 of the cover blank 68 are closest to the uppermostportion of the prongs, 124 and 126. The cover blank 68 can have aninitial longitudinal length L1 greater than the height H2 of the portionof the prongs, 124 and 126, extending beyond the mounting brackets, 128and 130. A portion of the cover blank 68 extending beyond the height H2of the prongs, 124 and 126, can be bonded together to form bond area 168which can ultimately form a seam such as the supporting element seam 174of cover 14.

As noted above, the cover blanks 68 can be manufactured in a ribbon 112of cover blanks 68 wherein the top edges 76 of two sequential coverblanks 68 can be adjacent to each other and the bottom edges 78 of twosequential cover blanks 68 can be adjacent to each other. As such, thecover blanks 68 can be said to be manufactured in an alternatingsequence of cover blanks 68. As the cover blanks 68 can be in analternating sequence in the ribbon 112 of cover blanks 68, every othercover blank 68 in the ribbon 112 may be in a ready configuration to beloaded on the first pallet 120 by placing the top edges 76 of the layers70 and 80 of the cover blank 68 closest to the mounting brackets, 128and 130, on the first pallet 120. To provide for efficiency in themanufacturing operation, the alternating cover blank 68 which may not bein a ready configuration to load on the first pallet 120 can be placedonto a cover blank 68 loading fixture 134 such as illustrated in FIGS.24 and 25. FIG. 24 provides a front view of a cover blank 68 loadingfixture 134 and FIG. 25 provides a side view of a cover blank 68 loadingfixture 134. The cover blank 68 loading fixture 134 can have a fixturebase 136 and a cover blank 68 support 138. As described above, invarious embodiments, the cover blank 68 can have a trapezoidalconfiguration. As the cover blank 68 can have a trapezoidalconfiguration, the cover blank 68 support 138 can also have atrapezoidal configuration. The cover blank 68 loading fixture 134 canprovide an alternative location for the loading of cover blanks 68 whichmay not be in ready configuration when separated from the ribbon 112 ofcover blanks 68 to be loaded onto the first pallet 120.

Referring to FIGS. 26-28, the loading of a cover blank 68 onto a firstpallet 120 and a cover blank 68 onto a cover blank 68 loading fixture134 can be illustrated. In an embodiment, a cover blank 68 can beconsidered to be in ready configuration for loading on the first pallet120 when, at the time the cover blank 68 can be separated from theribbon 112 of cover blanks 68, the cover blank 68 can be connected tothe ribbon 112 of cover blanks 68 via the bottom edge 78 of layers 70and 80, of the cover blank 68 and the top edges 76 of layers 70 and 80are the leading edge of the ribbon 112 of cover blanks 68. In such anembodiment, the cover blank 68 can be separated from the ribbon 112 bybreaking the perforations 106 between the connected bottom edges 78 ofthe cover blank 68 in the ribbon 112 and the next adjacent cover blank68 in the ribbon 112. The separated cover blank 68 can be directlyloaded onto the first pallet 120 at the first available location 118.

Referring to FIG. 26, this separated cover blank 68 can be loaded ontothe first pallet 120 with the top edges 76 of layers 70 and 80 of thecover blank 68 closest to the mounting brackets, 128 and 130, and thebottom edges 78 of layers 70 and 80 of cover blank 68 extending beyondthe prongs, 124 and 126. The cover blank 68 can be positioned such thatthe side seams, such as seam 74, are perpendicular to the plane of thefirst pallet 120. Positioning the cover blank 68 such that the side seam74 can be perpendicular to the place of the first pallet 120 can includerotating, in a clockwise or counter-clockwise direction, the cover blank68 about the prongs, 124 and 126, until the side seam 74 can beperpendicular to the plane of the first pallet 120. Positioning the sideseams, such as seam 74, perpendicular to the plane of the first pallet120 can prevent the removal element 16 from being associated with thevaginal insert 10 within the side seams, 72 and 74. If the removalelement 16 is associated with the vaginal insert 10 within the sideseams, 72 and 74, pulling on the removal element 16 during removal ofthe vaginal insert 10 from the vagina can weaken the side seams, 72 and74, of the vaginal insert 10, which can compromise the integrity of thevaginal insert 10.

In an embodiment in which the cover blanks 68 are manufactured in aribbon 112 with an alternating sequence of cover blanks 68 (such asillustrated in FIGS. 17 and 18), after a first cover blank 68 has beenseparated from the ribbon 112 and loaded onto the first pallet 120, thenext adjacent cover blank 68 can be separated from the ribbon 112 andloaded onto the cover blank 68 loading fixture 134 such as illustratedin FIG. 27. As illustrated in FIG. 27, the cover blank 68 can be loadedonto a cover blank 68 support 138 with the bottom edges 78 of layers 70and 80 closest to the base 136 of the cover blank 68 loading fixture134. With reference to FIG. 28, to transfer the cover blank 68 from thecover blank 68 loading fixture 134 to the first pallet 120, the coverblank 68 loading fixture 134 can be rotated 180° thereby positioning thecover blanks 68 located on the cover blank 68 loading fixture 134 intothe correct orientation for loading onto the first pallet 120. Coverblanks 68 which initially had the bottom edges 78 of layers 70 and 80 ofthe cover blank 68 as their leading edge when being separated from aribbon 112 of cover blanks 68 now have the top edges 76 of layers 70 and80 of the cover blank 68 as their leading edge and in the correctorientation to position the top edges 76 of layers 70 and 80 of thecover blank 68 closest to the mounting brackets, 128 and 130, of thefirst pallet 120.

With reference to FIGS. 17-28, in an exemplary embodiment, a firstpallet 120 can have six locations 118 upon which two-dimensional coverblanks 68 can be loaded and a cover blank 68 loading fixture 134 canhave six cover blank 68 supports 138 upon which two-dimensional coverblanks 68 can be loaded. In such an exemplary embodiment, the process ofloading multiple cover blanks 68 from a ribbon 112 of alternatingsequence cover blanks 68 (such as illustrated in FIGS. 17 and 18) ontothe first pallet 120 can include the steps of alternating the loading ofa cover blank 68 from the ribbon 112 onto the first pallet 120 with thetop edges 76 of layers 70 and 80 closest to the mounting brackets, 128and 130, followed by the loading of the next cover blank 68 in theribbon 112 onto the cover blank 68 loading fixture 134 with the bottomedges 78 of layers 70 and 80 closest to the base 136 of the cover blank68 loading fixture 134. These process steps can continue until all sixpositions 118 of the first pallet 120 and all six cover blank 68supports 138 of the cover blank 68 loading fixture 134 have a loadedcover blank 68. In such an embodiment, therefore, twelve cover blanks 68can be separated from the ribbon 112 of cover blanks 68. Once all sixpositions 118 of the first pallet 120 are loaded with a cover blank 68,the cover blanks 68 can be positioned such that the side seams, 72 and74, can be perpendicular to the plane of the first pallet 120. Themounting brackets, 128 and 130, can be operated such that the mountingbrackets, 128 and 130, and the prongs, 124 and 126, transition from theclosed configuration to an open configuration. The transition of themounting brackets, 128 and 130, from the closed configuration to an openconfiguration can be accomplished by pressing down on the base of amounting bracket, such as mounting bracket 128, and causing it to hingeopen. This movement can result in the hingedly attached mounting bracket130 to also transition to an open configuration. The prongs, 124 and126, in the open configuration, can push the layers, 70 and 80, of thecover blank 68 apart from each other, thereby rendering the cover blank68 into an open configuration. The first pallet 120 having the six coverblanks 68 loaded thereupon can be moved to the next station of themanufacturing process and an “empty” first pallet 120 can be obtained(thus, another first pallet 120). The cover blank 68 loading fixture 134can be inverted 180° over the “empty” first pallet 120 and the coverblanks 68, which had been loaded onto the cover blank 68 supports 138 ofthe cover blank 68 loading fixture 134, can be transferred to the“empty” first pallet 120 by sliding them off of the cover blank 68supports 138 and down onto the prongs, 124 and 126, of the “empty” firstpallet 120. Following the transfer of the six cover blanks 68 from thecover blank 68 loading fixture 134 to the “empty” first pallet 120, thecover blank 68 loading fixture 134 will be empty of cover blanks 68, thefirst pallet 120 which had been “empty” is now fully loaded with coverblanks 68 and can be moved to the next station of the manufacturingprocess, and the sequence of loading cover blanks 68 can begin againwith another empty first pallet 120 and an empty cover blank 68 loadingfixture 134.

The next station in the manufacturing process can include the pleatingand sealing of the bottom edges 78 of layers 70 and 80 of the coverblank 68. The pleating and sealing of the bottom edges 78 of layers 70and 80 of the cover blank 68 can result in the formation of a bond area168 which can ultimately form a seam, such as supporting element seam174 of the cover 14.

As described above, a cover blank 68 can be positioned on the firstpallet 120 such that the top edges 76 of the layers, 70 and 80, of thecover blank 68 can be positioned closest to the mounting brackets, 128and 130, of the first pallet 120. The bottom edges 78 of the layers, 70and 80, of the cover blank 68 can, therefore, extend beyond the prongs,124 and 126. The bottom edges 78 of the layers 70 and 80 can be bondedtogether to form a bond area 168. The bond area 168 can ultimatelybecome supporting element seam 174 and can ultimately be located nearthe supporting element 20 of the core 12.

FIGS. 29-34 provide exemplary illustrations of exemplary process stepswherein the bottom edges 78 of the layers 70 and 80 of the cover blank68 can be pleated and bonded together thereby forming bond area 168. Afirst pallet 120 having at least one open, three-dimensional cover blank68 thereupon, can enter a pleater module. The cover blank 68 can be inan open configuration as the prongs, 124 and 126, of the first pallet120 can be in an open configuration. The pleater module can pleat layers70 and 80 together thereby forming bond area 168. The bond area 168 canultimately become a supporting element seam 174 of a cover 14 and can belocated in proximity to the supporting element 20 of a core 12 of avaginal insert 10.

As described above with regards to FIGS. 26 and 28, a two-dimensionalcover blank 68 can be loaded onto a first pallet 120 and positioned suchthat the side seams, 72 and 74, can be perpendicular to the plane of thefirst pallet 120. The first pallet 120 can be conveyed to the pleatermodule with the side seams, 72 and 74, of the cover blank 68perpendicular to the plane of the first pallet 120.

FIG. 29 provides an exemplary illustration of a portion of a firstpallet 120 having a cover blank 68 loaded there-upon and held in an openconfiguration by pairs of opposing prongs, such as prongs 124. It is tobe understood that prongs 126 cooperate with prongs 124 to hold thecover blank 68 in an open configuration, however, only prongs 124 arevisible to the viewer in the illustration of FIG. 29. The pleater modulecan have tuck bars 150 which can operate in a paired fashion. Forexample, with reference to FIG. 29, two cover blanks 68 are visible inan open configuration and five tuck bars 150 are visible. The tuck bars150 can extend past the bottom edges 78 of the open cover blanks 68 andclose together to form the pleat of the layers 70 and 80 of the coverblanks 68. When the tuck bars 150 move into position in readiness topleat a cover blank 68, a tuck bar 150 of the pair of tuck bars 150 canbe positioned on one side of the cover blank 68, and the other tuck bar150 of the pair of tuck bars 150 can be positioned on the opposite sideof the cover blank 68. After the pair of tuck bars 150 have lowered intoposition, each tuck bar 150 moves into the side of a cover blank 68 tocreate a pleat. FIG. 30 provides a top view illustration of a coverblank 68 and two tuck bars 150, positioned in opposite relation to eachother, in ready position to pleat the cover blank 68. The directionalarrows can indicate the direction that each tuck bar 150 can move inorder to provide a pleat in the cover blank 68. It should be noted thatwhile FIG. 30 is a top view, the illustration of the first pallet 120 isnot visible in FIG. 30 to provide clarity of illustration.

As the tuck bars 150 move towards each other to create the pleats in thecover blank 68, the prongs, 124 and 126, can collapse together and clampthe cover blank 68 to keep the pleats from pulling out. The pleatedcover blank 68, when viewed in a top view, can resemble an “H”configuration. FIG. 31 provides a top view of the “H” configuration ofthe cover blank 68 after the pair of tuck bars 150 have pleated layers70 and 80 of the cover blank 68 and the prongs, 124 and 126, havetransitioned from the open configuration to a closed configuration.Referring to FIG. 32, it can be seen that a holder bar 152 can be movedinto position next to the pleated cover blank 68 to maintain the pleatedcover blank 68 in the pleated “H” configuration and/or to ensure thatthe prongs, 124 and 126, have collapsed together before the tuck bars150 are withdrawn. The tuck bars 150 can be withdrawn and the pleatedcover blank 68 can be conveyed to a bonding assembly for bonding of thepleated layers 70 and 80. The holder bar 152 can also be withdrawn priorto, during, or after conveyance of the first pallet 120 to the bondingassembly. The bonding of the pleated layers, 70 and 80, of the coverblank 68 can bond at least two layers of material together. In variousembodiments, as the pair of tuck bars 150 can fold layers 70 and 80inwards and towards each other, the bonding can be effected through atleast four layers of material. FIGS. 31 and 32 can each provide anillustration of the four layers of material of layers 70 and 80 of thecover blank 68 that can be bonded together to form the bond area 168.Also visible in FIGS. 31 and 32 is a pleat center 158 within the “H”configuration. The pleat center 158 can be the location of the pleatedcover blank 68 wherein material of layers 70 and 80 can be brought intoclose proximity with each other as a result of the movement of the tuckbars 150. In various embodiments, there can be less than a 10 mm gapbetween the material of layers 70 and 80 in the pleat center 158. Invarious embodiments, there can be from about 0, 1, 2, 3, 4, or 5 mm toabout 6, 7, 8, 9, or 10 mm gap between the material of layers 70 and 80in the pleat center 158.

FIG. 33 provides a top view of a pleated cover blank 68 within a bondingassembly. The bonding can occur by any means deemed suitable such as,but not limited to, adhesive, pressure bonding, thermal bonding,ultrasonic bonding, stitching, suturing, and/or welding. In theexemplary embodiment illustrated in FIG. 33, the pleated cover blank 68can be subjected to ultrasonic bonding to create a bond area 168 (shownin FIG. 34). Ultrasonic bonders can have an internal solenoid valve thatcan move the horn into and out of position when the bonding cycle hasbeen triggered. Any ultrasonic horn 154 and anvil 156 deemed suitablecan be utilized to form the bond area 168.

Once the bonding of each of the cover blanks 68 on the first pallet 120is completed, the first pallet 120 can be advanced to a trim removalstation. FIG. 34 provides an illustration of an exemplary embodiment ofa trim removal station. The bonding of layers 70 and 80 of the coverblank 68 can occur in the area of the layers 70 and 80 which extendsbeyond the height H2 of the prongs, 124 and 126. In various embodiments,all of the material of layers 70 and 80 of the cover blank 68 extendingbeyond the height H2 of the prongs, 124 and 126, can be bonded togetherto create a bond area 168. In various embodiments, less than all of thematerial of layers 70 and 80 of the cover blank 68 extending beyond theheight H2 of the prongs, 124 and 126, can be bonded together to create abond area 168. In such embodiments, an area of trim 164 can be locatedbetween the bond area 168 and the bottom edges 78 of the layers 70 and80 of the cover blank 68. The area of trim 164 can be removed in a trimremoval station. As the first pallet 120 can advance through the trimremoval station, a trim wheel 162, such as trim wheel 162 suspended froma support bracket 172, can nip the area of trim 164 and pull the area oftrim 164 upwards to separate the area of trim 164 from the bond area168. In various embodiments, the trim wheel 162 can be a pair offriction wheels. The area of trim 164 can be further pulled away fromthe bonded area 168 by any means deemed suitable, such as, for example,a vacuum 166. The hold down rollers 160 can prevent the cover blank 68from being pulled off of the prongs, 124 and 126. The hold down rollers160 can be suspended from a mounting bracket 170.

Following the pleating and bonding of edges 78 of layers 70 and 80 of acover blank 68, the cover blank 68 can have a single opening wherein aportion of at least one edge of layers 70 and 80 remains unbonded. Acore insertion module 180 can insert a core 12 into the cover blank 68through the opening of the cover blank 68. In various embodiments,inserting the core 12 into the cover blank 68 can be simply moving thecore 12 through the opening and into the space between layers 70 and 80of the cover blank 68. In such embodiments, the supporting element seam174 can be on an external surface of the cover 14. In variousembodiments, inserting the core 12 into the cover blank 68 can includethe steps of inverting the cover blank 68 and then moving the core 12through the opening and into the open space between layers 70 and 80 ofthe cover blank 68. In such embodiments, the supporting element seam 174can be located on an internal vaginal insert 10 surface. In variousembodiments, inserting the core 12 into the cover blank 68 can includethe step of inverting the cover blank 68 over and onto the core 12 atthe same time as the core 12 is being moved through the opening and intothe space between layers 70 and 80 of the cover blank 68. During theprocess of inserting a core 12 into the cover blank 68, the coreinsertion module 180 can also transfer the core 12 and cover blank 68combination to a second pallet 188.

FIG. 35 provides a front view illustration of an exemplary embodiment ofa core insertion module 180. The core insertion module 180 can receive acore 12 in a core compression tray 190, transfer the core 12 from thecore compression tray 190 into the cover blank 68 (provided on a firstpallet 120) and position the core 12 and cover blank 68 combination in asecond pallet 188. The transfer of the core 12 from the core compressiontray 190 into a cover blank 68 can include inserting the core 12 intothe cover blank 68 via any of the insertion methods described above.Once such insertion method—inverting the cover blank 68 at the same timeas moving the core 12 into the cover blank 68—can be further describedherein. To accomplish the insertion of the core 12 within the coverblank 68 and the transfer of the core 12 and cover blank 68 combinationto a second pallet 188, the core insertion module 180 can have threeprimary levels. A top level 182 can provide a location wherein a secondpallet 188 can be loaded for receipt of the core 12 and cover blank 68combination following insertion of the core 12 into the cover blank 68.The top level 182 can include a table 198 upon which the second pallet188 can be positioned. In various embodiments, the table 198 can move inan up and down motion within the core insertion module 180. For example,the table 198, with a second pallet 188 positioned thereupon can lowerto the middle level 184 of the core insertion module 180 to be in closerproximity to the first pallet 120, which can be positioned within themiddle level 184 of the core insertion module. The top level 182 canalso include pre-tuck rods 202 which can provide an initial tucking of acover blank 68 onto the core 12. A middle level 184 can include a barreldrum 194 and a barrel drum handle 196. A first pallet 120 can bepositioned within the barrel drum 194 and the barrel drum handle 196 canbe used to rotate the barrel drum 194 to invert the first pallet 120.The first pallet 120 can have at least one cover blank 68 positionedthereupon. The cover blank 68 can have side seams, 72 and 74, andsupporting element seam 174. The cover blank 68 can have an openingbetween the top edges 76 of layers 70 and 80 of the cover blank 68. Thetop edges 76 of the layers 70 and 80 can be positioned next to themounting brackets, 128 and 130, of a location 118 of the first pallet120. The middle level 184 can also include a core set tool 204 which canbe used to set a core 12 into the core compression tray 190. The core 12can be placed into an opening 220 in the core compression tray 190 andthe core set tool 204 can be used to push the core 12 further into theopening 220 such that the core 12 can be positioned below the topsurface 224 of the core compression tray 190. The core set tool 204 canhelp to maintain a uniform depth of core(s) 12 loaded into the corecompression tray 190. The lower level 186 can include the corecompression tray 190. A core 12 can be placed into an opening of thecore compression tray 190 and thereby readied for insertion into a coverblank 68. The core compression tray 190 can have a handle 192 which canbe used to move the core compression tray 190 between an open and closedconfiguration. The lower level 186 can also include push rods 200 whichcan push the core 12 upwards into the cover blank 68 and further intothe second pallet 188.

FIG. 36 provides a perspective view of an exemplary embodiment of themiddle level 184 and the lower level 186 of a core insertion module 180.The core compression tray 190 and the barrel drum 194 are each in anopen configuration and awaiting loading of cores 12 and a first pallet120, respectively. FIG. 37 provides a perspective view of an exemplaryembodiment of the middle level 184 and the lower level 186 of a coreinsertion module wherein the core compression tray 190 and the barreldrum 194 are each in a closed configuration. The core compression tray190 has been pushed into the core insertion module 180 and the barreldrum 194 has been rotated 180°. The rotation of the barrel drum 194 180°can invert the first pallet 120 located within the barrel drum 194. FIG.38A provides a perspective view of an exemplary embodiment of a corecompression tray 190 in the open and uncompressed configuration and FIG.38B provides a perspective view of an exemplary embodiment of a corecompression tray 190 in a closed and compressed configuration. The corecompression tray 190 can have a core compression tray handle 192, frontand rear jaws, 206 and 208, respectively, guide blocks 210, an opening220 for receiving the core(s) 12 to be loaded into the core compressiontray 190, at least one jaw connection mechanism, such as a rack andpinion arrangement 222, and a guide rail 212. A jaw connection mechanismcan connect jaws, 206 and 208, such that the jaws, 206 and 208, can movein tandom. Additional examples of jaw connection mechanism include, butare not limited to, slides, guide rails, and linear bearings. The corecompression tray 190, when transitioning from an open configuration to aclosed and compressed configuration, can maintain the shape of theopenings 220 (i.e., the aspect ratio between the axes can be maintained)and the jaws, 206 and 208, can compress to the same degree.

A core 12 can be placed into an opening 220 between guide blocks 210when loading cores 12 into the core compression tray 190. The guide rail212 can help to guide the core compression tray 190 as the corecompression tray 190 is pulled out from the core insertion module 180and pushed into the core insertion module 190. In various embodiments,the core compression tray 190 can compress the core(s) 12 loaded withinthe core compression tray 190 after moving the core compression tray 190into the core insertion module 180. In various embodiments, the corecompression tray 190 can compress the core(s) 12 loaded within the corecompression tray 190 as the core compression tray 190 is being pushedinto the core insertion module 180. To compress the core(s) 12 loadedwithin the core compression tray 190, the front and rear jaws, 206 and208, can shift 45° relative to the core insertion module 180 to compressthe cores 12. The movement of the jaws, 206 and 208, towards each otherto compress the core(s) 12 can be caused by air cylinder, pneumaticpower, hydraulic power, or manual manipulation of the core compressiontray 190. Pulling the core compression tray 190 out of the coreinsertion module 180 and into an open configuration can cause the jaws,206 and 208, to release their compression. In various embodiments, thecore compression tray 190 can have at least one opening 220 forreceiving a core 12. In various embodiments, the core compression tray190 can have from 1, 2, 3, 4, or 5 openings 220 to 6, 7, 8, 9, or 10openings 220. In various embodiments, the core compression tray 190 canhave the same number of openings 220 as locations 118 on the firstpallet 120.

Referring to FIGS. 39-42, schematic illustrations for the process ofoperating a core insertion module 180 can be illustrated. As these areschematic illustrations and for clarity of illustration, many of thesurrounding details of the core insertion module 180 have been removedfrom the illustrations. As can be seen in FIG. 39, an empty secondpallet 188 can be loaded into the top level 182 of the core insertionmodule 180. The second pallet 188 can have a base 214 and at least oneholder 216 for holding the core 12 and cover blank 68 combination. Whilethe second pallet 188 is illustrated as having one holder 216, thesecond pallet 188 can have from 1, 2, 3, 4, or 5 holders 216 to 6, 7, 8,9, or 10 holders 216. In various embodiments, the second pallet 188 canhave the same number of holders 216 as the number of locations 118 onthe first pallet 120. The empty second pallet 188 can be loaded onto asecond pallet table 198 which can be capable of moving down from the toplevel 182 of the core insertion module 180 to the first pallet 120located in the middle level 184 of the core insertion module 180. Thesecond pallet table 198 can have a transfer tube 218 which can guide thecore 12 and cover blank 68 combination during transition of the core 12and cover blank 68 combination into the second pallet 188. The transfertube 218 can also guide a pre-tuck rod 202 and a push rod 200 duringtheir respective movement within the core insertion module 180. A firstpallet 120 having at least one cover blank 68 loaded thereupon can beloaded into the middle level 184 of the core insertion module 180. Theloading of the first pallet 120 into the middle level 184 of the coreinsertion module 180 can include placing the first pallet 120 inside thebarrel drum 194 such that the supporting element seam 174 can beoriented upwards in the direction of the second pallet 188. As the firstpallet 120 exited the pleater module, the prongs, 124 and 126, of thefirst pallet 120 were in a closed configuration. As the first pallet 120can be moved and loaded into the middle level 184 of the core insertionmodule 180, the prongs, 124 and 126, can be transitioned from the closedconfiguration to an open configuration. It is to be noted that onlyprongs 124 are visible in FIG. 39, however, both pairs of prongs, 124and 126, can transition into an open configuration. The opening of theprongs, 124 and 126, also results in moving the layers, 70 and 80, in adirection away from each other, and, therefore, an opening of the coverblank 68. This opening of the cover blank 68 can create a flat surfaceof the cover blank 68 over the supporting element 20 of the core 12.

Cores 12 can be loaded into the core compression tray 190 with thesupporting arms 28 of the cores 12 oriented upwards in the direction ofthe second pallet 188. The core set tool 204 can be used to further pushthe core 12 into the opening 220 of the core compression tray 190 sothat the core 12 is below the top surface 224 of the core compressiontray 190. The core compression tray 190 can be pushed into the coreinsertion module 180. In various embodiments, pushing the corecompression tray 190 into the core insertion module 180 can cause thecore compression tray 190 to transition from an open and uncompressedconfiguration to a closed and compressed configuration. In variousembodiments, the core compression tray 190 can transition from an openand uncompressed configuration to a closed and compressed configurationafter the core compression tray 190 has been pushed into the coreinsertion module 180. In either case, the compression of the corecompression tray 190 can be actuated via air cylinder, pneumatic power,hydraulic power, or manual manipulation of the core compression tray190. It should be noted that the core compression tray 190, when in aclosed and compressed configuration, compresses the entire core 12, topto bottom. To compress the core 12, the guide blocks 210 of the frontand rear jaws, 206 and 208, can move towards each other at a 45° anglerelative to the core insertion module 180. In various embodiments inwhich the core compression tray 190 has transitioned from an open anduncompressed configuration after being pushed into the core insertionmodule 180, the compression of the core(s) 12 can occur at any of thefollowing times: prior to, during, or after the lowering of the secondpallet 188 from the top level 182 to the middle level 184 of the coreinsertion module 180 or prior to, during, or after the lowering of thepre-tuck rods 202 from the top level 182 to the middle level 184 topre-tuck the cover blank 68 into the core 12.

The barrel drum 194 can be inverted 180°, using the barrel drum handle196 to invert the barrel drum 194. The inversion of the barrel drum 194can cause the supporting element seam 174 of the cover blank 68 tochange orientation such that the supporting element seam 174 can beoriented in the direction of the core 12 and can be closer in proximityto the core 12. The inverted orientation of the cover blank 68 can beseen in FIG. 40.

Referring to FIG. 40, the second pallet table 198 can be lowered fromthe top level 182 to the middle level 184 so that the second pallet 188can be in closer proximity to the first pallet 120. While the transfertube 218 can be illustrated (such as in FIG. 40) as having a length suchthat the transfer tube 218 is close in proximity to the base of thefirst pallet 120, in various embodiments, the transfer tube 218 can havea length such that when the second pallet table 198 is lowered from thetop level 182 to the middle level 184, the transfer tube 218 can extendthrough the open area 132 in the first pallet 120 and can extend as faras the supporting element seam 174 of the cover blank 68. In variousembodiments, the transfer tube 218 can extend into the cover blank 68such that it can be closer in proximity to the supporting element seam174 of the cover blank 68.

Referring to FIG. 41, once the second pallet 188 is lowered from the toplevel 182 to the middle level 184 to be closer in proximity to the firstpallet 120, a pre-tuck rod 202 can lower from the top level 182 of thecore insertion module 180 and can move through the open area in thesecond pallet holder 216, through an open area in the second pallettransfer tube 218, through the open area 132 in the first pallet 120,and between the prongs, 124 and 126, of the first pallet to push thesupporting element seam 174 of the cover blank 68 against the supportingarms 28 of the core 12. In various embodiments, by pushing thesupporting element seam 174 of the cover blank 68 against the supportingarms 28 of the core 12, the pre-tuck bar 202 can partially insert thecover blank 68 into the supporting element 20 of the core 12 such thatwhen the process is completed the cover blank 68 can be loose on thecore 12. Following, the partial insertion of the cover blank 68 into thesupporting element 20 of the core 12, the pre-tuck bar 202 can beretracted.

Referring to FIG. 42, after the pre-tuck bar 202 can be retracted, thepush rod 200 can move upwards from the bottom level 186 of the coreinsertion module 180. The push rod 200 can move upwards through theopening 220 of the core compression tray 190, through the open area 132of the first pallet 120, and through the guide tube 218 of the secondpallet table 198. The push rod 200 can extend upwards to move thecompressed core 12 towards the second pallet 188. This pushing of thecompressed core 12 towards the second pallet 188 inserts the compressedcore 12 into the cover blank 68 by moving the compressed core 12 throughthe opening in the cover blank 68 and inverting the cover blank 68 overthe compressed core 12. The core 12 and cover blank 68 combination arealso pushed upwards into the second pallet holder 216 of the secondpallet 188 such as can be seen in FIG. 42. After the core 12 and coverblank 68 combination have reached the second pallet holder 216, the pushrod 200 and second pallet table 198 can all be retracted to theirrespective starting positions. In other words, the push rod 200 can belowered and the second pallet table 198 can be raised.

Following insertion of the core 12 into the cover blank 68 and followingthe loading of the core 12 and cover blank 68 combination in the secondpallet 188, the supporting arms 28 of the core and the supportingelement 20 region of the vaginal insert 10 can extend above the topsurface of the second pallet holder 216. As described herein, a removalelement 16 can be associated with the vaginal insert 10 at thesupporting element 20 region of the vaginal insert 10. The second pallet188 with the core 12 and cover blank 68 combination can be conveyed to astring and knot module. In various embodiments, the string and knotmodule can associate a removal element 16 with the supporting element 20region of the vaginal insert 10 and can create two knots in the removalelement 16. The double knotting of the removal element 16 can hold theremoval element 16 in place on the vaginal insert 10 and can provide awearer of the vaginal insert 10 a place to grasp the removal element 16during withdrawal of the vaginal insert 10 from the vagina.

The core 12 and cover blank 68 combination in the second pallet 188 canenter a string and knot module with the supporting element seam 174exposed above the second pallet holder 216. Following processing by thestring and knot module, the top edges 72 of layers 70 and 80 of thecover blank 68 can still be unbonded and a removal element 16 can beattached to the cover blank 68 in the area of the supporting elementseam 174 and knotted twice. FIG. 43 provides a schematic exemplaryembodiment of the product following processing in the string and knotmodule.

The string and knot module can attach a removal element 16 to the coverblank 68 and can create lower and upper knots, 230 and 232, on theremoval element 16. The string and knot module can use severalmechanical assemblies and air/vacuum to control the removal element 16as it is metered, cut and knotted. Assemblies associated with thestringing and knotting processes include: knotting block assemblies, aneedle assembly, scissor assemblies, and cover blank 68 and removalelement clamping assemblies.

The overall process in the string and knot module has two main steps.The first step can be to insert a removal element 16 into the core 12and cover blank 68 combination and the second step can be to create twoknots in the removal element 16. FIGS. 44-46 provide schematicillustrations of embodiments of process steps for inserting a removalelement 16, such as, for example, a string 244 into the core 12 andcover blank 68 combination and FIGS. 47-54 provide schematicillustrations of embodiments of process steps for double knotting aremoval element 16.

Referring to FIG. 44, a schematic illustration of a stringing module canbe illustrated. The stringing module can include a spool 246 of string244. The spool 246 of string 244 can be located on an unwind stand andthe string 244 can be allowed to flow freely from the spool 246 duringthe overall stringing process. In various embodiments, a mechanicalweight can be attached to the string 244 to maintain tension in thestring 244. The string 244 can move through a string block 240 that canmove toward a needle 238 and back. In various embodiments, the movementof the string 244 through the string block 240 can be effected by an airpressure differential. In various embodiments, the air pressuredifferential can be such that the area of higher pressure is located inthe area of the core 12 and cover blank 68 combination. In variousembodiments, the movement of the string 244 through the string block 240can be effected by pushing on the string 244 with air. In variousembodiments, the movement of the string 244 through the string block 240can occur via pulling on the string 244 with a vacuum. As the stringblock 240 can move towards the needle 238, the movement of the stringblock 240 can move the string 244 by the same amount as the movement ofthe string block 240. An internal string clamp 242, located within thestring block 240, can be utilized to stop the string 244 from movingwhen it is desired that the string 244 not move. A hollow needle 238 canallow the string 244 to move through the needle 238. In variousembodiments, any type of component providing a channel for the string244 can be utilized in place of a hollow needle 238. Opposite to theneedle 238, and on the other side of the core 12 and cover blank 68combination, a string pulling clamp mechanism 234 can be located. Thestring pulling clamp mechanism 234 can move forwards/backwards with theneedle 238 mechanisms. A string clamp 236 within the stringpulling/clamp mechanism 234 can be used to hold the string 244 after theneedle 238 has pierced the cover blank 68 and pushed the string 244through the cover blank 68.

Referring to FIG. 45, a schematic view of the basic process of providinga string 244 can be illustrated. It is to be noted that, while notillustrated in FIG. 45, two funnels 256 associated with the lowerknotting block 262 can be lowered into position and on either side ofthe cover blank 68 prior to the stringing of the cover blank 68. Moredetails on the funnels 256 and the knotting process will be providedbelow. A second pallet 188 holding a core 12 and cover blank 68combination can be indexed into position for the provision of theremoval element 16, such as in the form of string 244. As the secondpallet 188 can be indexed into position, the core 12 and cover blank 68combination can be rotated. The rotation can provide that the needle 238and the string 244 may not pierce the supporting element seam 174 aspiercing of the supporting element seam 174 can weaken the overallsupporting element seam 174.

Air can be pushed up towards the second pallet base 214 from underneaththe second pallet 188. The air can further move through the secondpallet holder 216 which can “puff up” and tent the cover blank 68 abovethe supporting arms 28 of the core 12. Following the “puffing up” andtenting of the cover blank 68, cover blank 68 clamps, 248 and 250, canclose on the cover blank 68 and the core 12. The closure of the coverblank clamps, 248 and 250, can collapse the supporting arms 28 of thecore 12 as well as the cover blank 68. As the cover blank 68 was “puffedup” and tented prior to the closure of the cover blank clamps, 248 and250, a portion of the cover blank 68 can extend above the height of thecover blank clamps, 248 and 250. The air movement underneath the secondpallet 188 and the closure of the cover blank clamps, 248 and 250, can,therefore, cause the cover blank 68 to tent up and provide a locationwherein the needle 238 can thread the string 244 through.

The two funnels 256 associated with the lower knotting block can lowerwith one funnel 256 on each side of the tented cover blank 68. To movethe string 244 through the cover blank 68, the needle 238 can be movedforward towards the cover blank 68. The needle 238 can move through anopening in the first funnel 256, four layers of the pleated and tentedcover blank 68, and through an opening in the second funnel 256 locatedon the opposite side of the cover blank 68. The string block mechanism240 can move towards the back of the needle 238 and can feed about ½inch of string 244 through the needle 238. The string 244, which hasbeen fed by the needle 238 through the first funnel 256, the four layersof the pleated and tented cover blank 68, and the second funnel 256, canbe captured by the string clamp 236 in the string pulling clampmechanism 234 which can also move forwards towards the cover blank 68.The string pulling clamp 236 can clamp the end of the string 244 and thestring block mechanism 240 can be released.

Referring to FIG. 46, the needle 238 and the string pulling clampmechanism 234 can each move back to their starting positions. As thestring 244 can be clamped and held by the string clamp 236 in the stringpulling clamp mechanism 234, the string 244 can be pulled by the stringpulling clamp mechanism 234 and the distance of the move backwards bythe string pulling clamp mechanism 234 can set the length of the string244. The string 244 can be pinched in the middle, at the location of thetented cover blank 68, by a string pincher 254 to prevent it fromsliding during the knotting process. The pinch in the string 244 can beheld until the first knot is created. Once the desired length of string244 is obtained and the string 244 has been pinched by a string pincher254, the string can be cut by a string cutter 252 located in proximityto the needle 238 and the string push clamp 242 can be clamped toprepare the string 244 for the next cycle.

The knotting of the string 244 can start at the same time as the string244 feed through the first funnel 256, through the four layers ofpleated and tented cover blank 68, and through the second funnel 256 tothe string pulling clamp mechanism 234. The knotting can include thesteps of lowering the upper and lower knotting blocks, 260 and 262,respectively, and funnels 256 into position when the core 12 and coverblank 68 is first clamped. The funnels 256 can be in position before theneedle 238 is moved through the core 12 and cover blank 68. Such asillustrated in FIG. 47, the string 244 can be fed through two funnels256 which are located on each side of the pleated and tented cover blank68. It is to be noted that the funnels 256 can be used to position thestring 244 into the knotting blocks. The funnels 256 can be opened whenthey are in the stringing position by following a mechanical cam. Whenthe knotting blocks, 260 and 262, move upwards from the stringer module,the funnels 256 exit the mechanical cam and close. In variousembodiments, the funnels 256 can be held closed by the use of smallmagnets. Each of the knotting blocks, 260 and 262, can moveindependently of the other knotting block, 260 and 262. Each of theknotting blocks, 260 and 262, can have upper and lower portions whichcan also move independently. Upper knotting block 260 can have upperportion 228 and lower portion 226. Lower knotting block 262 can haveupper portion 278 and lower portion 276.

Once the string 244 is cut, such as illustrated in FIG. 47, the knottingblocks, 260 and 262, and the funnels 256 move up to straighten thestring such as illustrated in FIG. 48. The string 244 remains pinched bythe string pincher 254, however, the string 244 can be released from thestring pulling clamp mechanism 234. The entry point 258 of the stringinto the lower knotting block 262 can be at the bottom of the lowerknotting block 262. The string pincher 254 can continue to hold thestring 244 while the funnels 256 and upper and lower knotting blocks,260 and 262, are lifted.

Referring to FIG. 49, once the string 244 has been lifted upwards by theupward movement of the funnels 256 and the upper and lower knottingblocks, 260 and 262, string holders 270 can be utilized to momentarilyhold up the string 244 and prevent it from collapsing towards theproducts. The string holders 270 can support the weight of the string244 until the string 244 can be brought into the knotting blocks, 260and 262. From this point forward, the funnels 256 can remain closed forthe remainder of the process.

Referring to FIG. 50, the knotting blocks, 260 and 262, can be loweredto the string holders 270 and a vacuum can be used to pull the string244 through the knotting blocks, 260 and 262. The knotting blocks, 260and 262, can have a string path 274 that can create a knot loop aroundcenter pins, such as center pins 264 and 266. The center pins, 264 and266, can be used to force a knot to be created at a specific spot on thestring 244. In various embodiments, the center pins, 264 and 266, can belocated in the upper portions, 228 and 278, of the knotting blocks, 260and 262, respectively. For example, center pin 264 can be located inupper portion 278 of the lower knotting block 262 and center pin 266 canbe located in upper portion 228 of the upper knotting block 260. Oncethe string 244 can be fed through the string path 274 and around acenter pin, 264 or 266, a clamp 268 can be used to hold the string 244while the knot is created. The string path 274 can be illustrated inFIG. 51. For clarity, the knotting block details are not shown in theillustration of FIG. 51, however, the string path 274 illustrated candemonstrate the path that the string 244 can follow around center pin264 in the lower knotting block 262 and center pin 266 in the upperknotting block 260. The string path 274 can be an “overhand knot” pathin both the upper and lower knotting blocks, 260 and 262. In variousembodiments, the upper knotting block 260 portion of the string path 274can be at a 90° and to the lower knotting block 262 portion of thestring path 274.

Referring to FIG. 50, the string 244 can follow the string path 274which can take the string 244 around center pin 264 located in the upperportion 278 of lower knotting block 262. The string 244 can continue tofollow the string path 274 to the lower portion 226 of the upperknotting block 260 where the string 244 can be clamped by the stringclamp 268 located in the lower portion 226 of the upper knotting block260.

As can be seen in the schematic illustration of FIG. 52, the upperknotting block 260 can move upwards which can cause the upper and lowerportions, 278 and 276, of the lower knotting block 262 to open. Theopening of the upper and lower portions, 278 and 276, of the lowerknotting block 262 can allow the center pin 264 to retract. As the upperknotting block 260 can continue to move upwards, the string 244 can betightened and the portion of the string 244 which had been wrappedaround the center pin 264 can form the lower knot 230. The lower knot230 can be tightened by the upward movement of the upper knotting block260 and the string clamp 268 in the lower portion 226 of the upperknotting block 260. The lower knotting block 262 can remain open for therest of the process. The string pincher 254 can also be released at thispoint.

After the lower knot 230 is complete, the upper knotting block 260 canmove downward to take the string 244 in again to form a second knot 232.As with the lower knot 230, the string 244 follows the string path 274that can wrap the string 244 around the center pin 266 in the upperportion 228 of the upper knotting block 260. FIG. 53 provides aschematic representation of such a process step. Referring to FIG. 54,once the string 244 has wrapped around the center pin 266 in the upperportion 228 of the upper knotting block 260, a string clamp 268 in theupper portion 228 of the upper knotting block 260 can be used to holdthe string 244 while the knot 232 is tightened. The upper portion 228 ofthe upper knotting block 260 can move upwards and open the upper portion228 from the lower portion 226 of the upper knotting block 260 to allowthe center pin 266 to retract. As the upper portion 228 of the upperknotting block 260 can continue to move upwards, the string 244 can betightened and the portion of the string 244 which had been wrappedaround the center pin 266 can form the upper knot 232. The upper knot232 can be tightened by the upward movement of the upper portion 228 ofthe upper knotting block 260.

FIG. 55 is a schematic illustration that can demonstrate that once theknots, 230 and 232, can be formed, the knotting blocks, 260 and 262, canbe moved upwards to their starting positions. A string control mechanism272 can be moved forward to catch the strings and prevent them frombeing snapped towards the core 12 and cover blank 68 combination in thesecond pallet 188 while the second pallet 188 indexes towards the nextportion of the manufacturing process and the cover clamps, 248 and 250,can be retracted. It is to be noted that while the knotting module canbe described as having an upper knotting block 260 and a lower knottingblock 262, in various embodiments, the knotting module can have only oneknotting block. In such embodiments, the knotting module can produce afirst knot in the string, reposition the string within the same knottingblock, and create a second knot into the string.

Following the attachment of the string 244 which can form the removalelement 16, it can be beneficial to transfer the core 12 and cover blank68 combination to a third pallet 280. The transfer of the core 12 andcover blank 68 combination to the third pallet 280 can allow for theinversion of the core 12 and cover blank 68 combination and allow forthe ability to bond the top edges 76 of the layers 70 and 80 of thecover blank 68 thereby fully enclosing the core 12 and converting thecover blank 68 to a cover 14. FIG. 56 provides a perspective view of anexemplary embodiment of the core 12 and cover blank 68 combination inwhich the core 12 is positioned within the cover blank 68 with a removalelement 16 attached at the supporting element 20 region, however, oneend of the cover blank 68 remains unbonded. FIG. 57 provides aperspective view of an exemplary embodiment of a third pallet 280 inwhich the core 12 and cover blank 68 combination can be reversed fromthe configuration illustrated in FIG. 56. In other words, the core 12and cover blank 68 combination in the second pallet 188 provides for theremoval element 16 to be attached to the cover blank 68 and visibleexternal to the second pallet 188. The core 12 and cover blank 68combination of FIG. 57 illustrates that, following transfer from thesecond pallet 188 to the third pallet 280, the removal element 16 andthe supporting element 20 of the core 12 and cover blank 68 combinationare within the interior of the third pallet 280 and the anchoringelement 18 extends beyond the outside surface of the third pallet 280.

Schematic illustrations for the process of the transfer of the core 12and cover blank 68 combinations from the second pallet 188 to a thirdpallet 280 can be illustrated in FIGS. 58-64 with further reference toFIGS. 65-67 regarding the transfer module 300. The transfer module 300can have a second pallet 188 loading zone 302, removal element wipers288, a third pallet 280 loading zone 304, an inverter 308 and aninverter handle 322, a compressor 284 and compressor handle 286, pushrods 292 and a push rod handle 294, and foot peddle 306. The inverter308 can rotate 180° and can also raise and lower the second pallet 188in its inverted orientation (i.e., following rotation of the inverter308). A second pallet 188 can be conveyed to the second pallet loadingzone 302 of the transfer module 300 following attachment of the removalelement 16 to the cover blank 68. When conveying the second pallet 188into the second pallet loading zone 302, the second pallet 188 can bepassed through a set of removal element wipers 288 to ensure that theremoval elements 16 will not get caught in any components of thetransfer module 300 such as guide rails. The second pallet 188 can beloaded onto an inverter 308 which can invert the second pallet 188 intoposition for the transfer of the core 12 and cover blank 68 combination.The second pallet loading zone 304 and the inverter 308 can bepositioned above the compressor 284. An empty third pallet 280 can beloaded into the third pallet loading zone 304. The third pallet loadingzone 304 can include a lift tray which can lift the third pallet 280upwards towards the compressor 284. The third pallet loading zone 304can, therefore, be positioned below the compressor 284. The third pallet280 can have locations 290 for receiving the core 12 and cover blank 68combinations. The third pallet 280 can have as many locations as aredeemed suitable. In an embodiment, the third pallet 280 can have atleast one location 290. In an embodiment, the third pallet can have from1, 2, 3, 4, or 5 locations 290 to 6, 7, 8, 9 or 10 locations 290. Invarious embodiments, the third pallet 280 can have the same number oflocations 290 as the number of locations 118 on the first pallet 120.

Referring to FIG. 58, the second pallet 188 can be loaded into a secondpallet loading zone 302 located above a compressor 284 and placed on theinverter 308 and the third pallet can be loaded into a third palletloading zone 304 located below a compressor 284. The second pallet canbe loaded with the core 12 and cover blank 68 combination facing upwardaway from the compressor 284. Referring to FIG. 59, the second pallet188 can be inverted by grasping the inverter handle 322 and rotating theinverter 180° until the core 12 and cover blank 68 combination areoriented downwards in the direction of the compressor 284. Referring toFIG. 60 the inverter 308 and the second pallet 188 can be lowered to itslowest position such that the supporting element 20 and the removalelement 16 are positioned with the compressor 284. A vacuum can beutilized to assist in drawing the removal element 16 into the openingsof the compressor 284. Using the foot peddle 306, the foot peddle 306can be pressed down upon which can cause an associated lever to raisethe third pallet 290 upwards towards the compressor 284. Referring toFIG. 61, the compressor handle 286 can be actuated to collapse the jawsof the compressor 284 and move the compression blocks 298 located withinthe compressor 284 base 296 towards each other. The compression blocks298 can shift at a 45° angle relative to the transfer module 300. Toenable the shifting, the compressor 284 can have jaw connectionmechanisms such as, but not limited to, slides, guide rails, linearbearings, or rack and pinion arrangements. The compression can collapsethe core 12 and the cover blank 68 combination to enable transfer of thecore 12 and cover blank 68 combination from the second pallet 188 to thethird pallet 290. In various embodiments, the compression of thecompressor 284 can be actuated via air cylinder, pneumatic power,hydraulic power, or manual manipulation of the compressor 284. Referringto FIG. 62, push rods 292 can be activated to move through an open areain the base of the second pallet 188 and push the core 12 and coverblank 68 combination out of the second pallet 188 and into the thirdpallet 280. Referring to FIG. 63, following the transfer of the core 12and cover blank 68 combination from the second pallet 188 to the thirdpallet 280, the push rods 292 can be retracted and the second pallet 188can be inverted and returned to the second pallet's 188 originalstarting position. The compressor handle 286 can be actuated to releasethe compressor 284 and the third pallet 280 can be lowered by releasingthe foot pedal 306. The third pallet 280 can continue on in themanufacturing process, such as illustrated in FIG. 64.

The third pallet 280 can convey the core 12 and cover blank 68combination to a pleater module. As the cover blank 68 can already haveside seams, 72 and 74, and a supporting element seam 174, the pleatermodule can provide an anchoring element seam for the cover blank 68.Similar to the formation of the pleats in the layers 70 and 80 of thecover blank 68 earlier in the manufacturing process, the top edges ofthe layers 70 and 80 of the cover blank 68 can be pleated in an “H”configuration, as viewed from the top of the cover blank 68. After thecover blank 68 can be pleated, the layers 70 and 80 of the cover blank68 can be bonded to create an anchor element seam which can complete thecover 14 that can fully enclose the core 12 within the cover 14.

Referring to FIGS. 68-76, the pleater module can pleat and bond thelayers 70 and 80 of the cover blank 68 to create an anchor end seam.FIG. 68 provides a front view and FIG. 69 provides a top view of a thirdpallet 280 as it can be conveyed to the pleater module. The anchoringelement 18 of the core 12 can extend above the third pallet 280 and aportion of cover blank 68 material can extend beyond the anchoringelement 18. FIG. 70 can provide a front view and FIG. 71 can provide atop view of the lowering of pins 310 inside the cover blank 68 and themovement of tuck bars 312 towards the sides and middle of the coverblank 68. In an embodiment, four pins 310 can assist in maintaining theopen configuration of the cover blank 68. FIG. 72 can provide a frontview and FIG. 73 can provide a top view of the movement of the tuck bars312 into the cover blank 68 between the pins 310. This movement of thetuck bars 312 can create the “H” configuration of the pleat. FIG. 74 canprovide an illustration that once the pleat has been created, the pins310 can be removed from within the cover blank 68. After the pins 310are removed from within the cover blank 68, the layers 70 and 80 of thecover blank 68 can be bonded, such as, for example, being ultrasonicallywelded such as illustrated in FIG. 75. Once the bonding of the layers 70and 80 of the cover blank 68 is complete, the tuck bars 312 can retractto their starting positions and the cover blank 68 can have a bondedarea 318 which can ultimately become the anchor element seam for thecover blank 68. Once the anchor element seam for the cover blank 68 canbe formed, the core 12 can be fully enclosed within the cover 14. As canbe seen in the exemplary embodiment illustrated in FIG. 76, an area oftrim 320 can be created during the bonding process. This area of trim320 can be removed in a fashion similar to the methods previouslydescribed for removing areas of trim.

While the cover 14 can have a core 12 enclosed within, it may bedesirable to conform the cover 14 to the overall shape and configurationof the core 12. Reasons and methods for conforming a cover 14 to a core12 have been previously discussed. One method, such as, forming a bandand attaching the band can be further detailed herein. A band formingmodule can apply a band 344 on cover 14 of the vaginal insert 10. Invarious embodiments, the band 344 can be configured from a material suchas a nonwoven material. In various embodiments, the band 344 can beconfigured from a material such as a film. In various embodiments, theband 344 can be configured from a woven material. In variousembodiments, the band 344 can be configured from a material which can bethe same material used to configure the cover 14.

The band forming process can produce a small band 344 of material thatcan be placed on the cover 14 of the vaginal insert 10. The process offorming a band 344 can be illustrated in FIG. 77. The material 330 forthe band 344 can be fed from a roll and can be routed via a mechanicalweb guide 332 to feed rollers 334. The material 330 can have a widthfrom about 3, 4 or 5 mm to about 6, 7 or 8 mm. In an embodiment, thematerial 330 can have a width of about 6 mm. In an embodiment, one ofthe rollers 334 can be controlled via a servo motor and the other of thefeed rollers 334 can be driven via friction. Each friction driven rollercan have an adjustable spring tensioner to increase or decrease theforce of the rollers 334. In various embodiments, the movement of thematerial 330 through the web guide 332 can be effected by an airpressure differential. In various embodiments, the air pressuredifferential can be such that the area of lower pressure is located inthe area of the mandrel 340. In an embodiment, the material 330 can movethrough the mechanical web guide 332 by being pushed through withcompressed air. In various embodiments, the movement of the material 330through the web guide 332 can occur via pulling on the material 330 witha vacuum. The feed rollers 334 can feed the material 330 into a secondweb guide mechanism 336. The second web guide mechanism 336 can utilizecompressed air to feed the material 330 onto the mandrel 340. Thematerial 330 can be fed to a mandrel 340 and the mandrel can use avacuum to control the material 330 once it is placed on the mandrel.Once the desired length of material 330 has been fed onto the mandrel340, a cutter, such as scissors 338, on the second web guide mechanism336 can cut the material 330. The mandrel 340 can rotate and thematerial 330 can wrap around the mandrel 340. FIG. 78 provides anillustration of a vacuum hole pattern 350 on the mandrel 340 to maintainthe material 330 for the band 344 in place on the mandrel 340. Thepattern 350 can have a series of horizontal holes to the left of abackwards facing “C.” The material 330 can be placed onto the mandrel atthe right hand side of the “C” (i.e., the three vertical holes in thepattern 350) and the mandrel 340 and the pattern 350 can continue torotate until the end of the cut material 330 overlaps with the threevertical holes in the pattern 350. Once the material 330 has overlappeditself on the mandrel 340, the material 330 can be bonded to itself,such as, for example, through the use of an ultrasonic horn 342 or anyother method of bonding mentioned herein—such as, for example, adhesive,thermal bonding and/or pressure bonding. The bonding of the material 330to itself can occur in the open area of the backwards “C” in the pattern350. The bonding of the material 330 to itself can create the band 344which can be placed onto the cover 14 of the vaginal insert 10.

Once a band 344 has been manufactured it can be placed on a cover 14 ofa vaginal insert 10. FIG. 79 can illustrate the process of placing aband 344 on a cover 14 of a vaginal insert 10. The mandrel 340 can havetwo sections: the top section can be connected to a vacuum source andcan be the location where the material 330 can wrap around the mandrel340 to form the band 344. The bottom section of the mandrel can behollow to allow the vaginal insert 10 to be pushed inside the mandrel toenable the band 344 to be slipped onto the cover 14 of the vaginalinsert 10. The anchoring element 18 of the vaginal insert 10 can becompressed. Following compression of the anchoring element 18 of thevaginal insert 10, the third pallet 280 in which the vaginal insert 10is located can be raised up and the compressed anchoring element 18 ofthe vaginal insert 10 can be positioned inside the mandrel 340. A bandstripper 356 located on the mandrel 340, and above the band 344, canmove down the mandrel 340 and towards the vaginal insert 10. As the bandstripper 356 can move down the mandrel, the band stripper 356 can movethe band 344 which had been in position on the mandrel 340 down over thecompressed anchor element 18 of the vaginal insert 10. The third pallet280 can be lowered, the anchoring element 18 of the vaginal insert canbe removed from inside the mandrel 340 and the band 344 can be inposition on the vaginal insert 10.

A heat staking process can weld the band 344 to cover 14 of the vaginalinsert 10 on both the front and back sides of the vaginal insert 10.FIG. 80 provides a schematic of an exemplary process of heat staking theband 344. Heated elements 358 can be briefly compressed to the band 344on the cover 14 of the vaginal insert 10 to form the weld which canmaintain the band 344 in position on the cover 14 of the vaginal insert10.

Following the manufacture of the vaginal insert 10 and the conformationof the cover 14 to the core 12 of the vaginal insert 10, the vaginalinsert 10 can be placed into an applicator 40 such as described hereinto ease insertion of the vaginal insert 10 into the vagina.

It is to be noted that while the description herein provides anexemplary embodiment of the process of manufacturing a vaginal insert10, additional embodiments are also contemplated. For example, theexemplary embodiment of the process of manufacture described herein cangenerally describe inserting a core 12 into a cover blank 68 through anopening between the top edges 76 of the two layers 70 and 80 of thecover blank 68. It is to be noted that, in various embodiments,insertion of the core 12 into the cover blank 68 can occur through anopening between bottom edges 78 of the two layers, 70 and 80, of thecover blank 68 or through an opening between side edges of layers 70 and80 of the cover blank 68. It is also contemplated that, while thedescription herein generally describes bonding the bottom edges 78 ofthe layers 70 and 80 of a cover blank 68 prior to bonding of the topedges 76 of layers 70 and 80 of the cover blank 68, in variousembodiments, the top edges 76 of layers 70 and 80 of the cover blank 68can be bonded prior to the bonding of the bottom edges 78 of layers 70and 80 of the cover blank 68.

It is also noted that while the description herein generally provides anexemplary embodiment of each of the core insertion module 180, thestringer and knot modules, the transfer module 300, the pleater module,and the band forming module, additional embodiments are alsocontemplated. For example, in some portions of the description herein,some components of the various module are described as being “above” or“below” other components of the same module, and in some portions of thedescription herein, some components are described as being in aparticular “level” of the module, such as, a “top level,” “middlelevel,” or “bottom level.” It is contemplated that the orientation ofthe modules can be reversed such that, for example, components that arecurrently described as being “above” another component can, in variouscontemplated embodiments, be “below” that component and that somecomponents which are currently described as being in a “top level” can,in various contemplated embodiments, be in a “bottom level.”

In the interests of brevity and conciseness, any ranges of values setforth in this disclosure contemplate all values within the range and areto be construed as support for claims reciting any sub-ranges havingendpoints which are whole number values within the specified range inquestion. By way of hypothetical example, a disclosure of a range offrom 1 to 5 shall be considered to support claims to any of thefollowing ranges: 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; 2 to3; 3 to 5; 3 to 4; and 4 to 5.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by references, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method of manufacturing a vaginal insert, themethod comprising the steps of: a. providing a core capable oftransitioning between a compressed configuration and a radially expandedconfiguration, the core comprising: i. an anchoring element; ii. asupporting element; and iii. a node connecting the anchoring element andthe supporting element; b. providing a cover blank, the cover blank,when viewed in a flat configuration prior to a step of inserting thecore into the cover blank, comprising: i. a first layer of material anda second layer of material in a face-to-face relationship with the firstlayer of material; ii. a four-sided trapezoidal shape when viewed in aflat configuration prior to the step of inserting the core into thecover blank, wherein two sides of the four-sided trapezoidal shape areprovided by a first side seam and a second side seam bonding the firstlayer of material to the second layer of material, a third side of thefour-sided trapezoidal shape is provided by a third side seam bondingthe first layer of material to the second layer of material wherein thethird side seam extends between and connects the first side seam and thesecond side seam, and the fourth side of the four-sided trapezoidalshape is provided by an unbonded opening between a pair of overlappingend edges wherein a first end edge of the pair of overlapping end edgesis a portion of the first layer of material and a second end edge of thepair of overlapping end edges is a portion of the second layer ofmaterial, wherein the fourth side of the four-sided trapezoidal shape isparallel to the third side and extends between and connects the firstside seam and the second side seam; and iii. a first width dimension ofthe third side of the trapezoidal shape and a second width dimension ofthe fourth side of the trapezoidal shape which is greater than the firstwidth dimension; c. inserting the core into the cover blank by placingthe third side of the cover blank into contact with a portion of thesupporting element of the core and inverting the cover blank over thecore resulting in a core and cover blank combination and the third sideof the cover blank in proximity to the supporting element of the coreand the fourth side of the cover blank in proximity to the anchoringelement of the core; d. attaching a removal element to the cover blank;e. bonding together the portions of the first layer of material and thesecond layer of material forming the fourth side of the four-sidedtrapezoidal shape of the cover blank to form a fourth side seam in theproximity to the anchoring element of the core to fully encase the corewithin the four side seams thereby converting the cover blank into acover; and f. conforming the cover to the core in the area of the nodeof the core by reducing the dimension of the cover at the node of thecore, wherein the step of reducing the dimension of the cover at thenode further comprises a step of wrapping a band of material around thecover at the node of the core and maintaining the reduced dimension ofthe cover by attaching the band of material to the cover.
 2. The methodof claim 1 wherein the step of attaching the removal element to thecover blank further comprises the step of rotating the core and coverblank combination.